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NASA NTRS2015

High-Temperature, Wirebondless, Ultracompact Wide Bandgap Power Semiconductor Modules

Silicon carbide (SiC) and other wide bandgap semiconductors offer great promise of high power rating, high operating temperature, simple thermal management, and ultrahigh power density for both space and commercial power electronic systems. However, this great potential is seriously limited by the lack of reliable high-temperature device packaging technology. This Phase II project developed an ultracompact hybrid power module packaging technology based on the use of double lead frames and direct lead frame-to-chip transient liquid phase (TLP) bonding that allows device operation up to 450 degC. The new power module will have a very small form factor with 3-5X reduction in size and weight from the prior art, and it will be capable of operating from 450 degC to -125 degC. This technology will have a profound impact on power electronics and energy conversion technologies and help to conserve energy and the environment as well as reduce the nation's dependence on fossil fuels.

Elmes, John↗

NASA NTRS2008

Evaluation of Silicon-on-Insulator HTOP-01 Operational Amplifier for Wide Temperature Operation

Electronics capable of operation under extreme temperatures are required in many of NASA space exploration missions. Aerospace and military applications, as well as some terrestrial industries constitute environments where electronic systems are anticipated to be exposed to extreme temperatures and wide-range thermal swings. Electronics that are able to withstand and operate efficiently in such harsh environments would simplify, if not eliminate, traditional thermal control elements and their associated structures for proper ambient operation. As a result, overall system mass would be reduced, design would be simplified, and reliability would be improved. Electronic parts that are built utilizing silicon-on-insulator (SOI) technology are known to offer better radiation-tolerance compared to their conventional silicon counterparts, provide faster switching, and consume less power. They also exhibit reduced leakage current and, thus, they are often tailored for high temperature operation. These attributes make SOI-based devices suitable for use in harsh environments where extreme temperatures and wide thermal swings are anticipated. A new operational amplifier, based on silicon-on-insulator technology and geared for high temperature well-logging applications, was recently introduced by Honeywell Corporation. This HTOP-01 dual precision operational amplifier is a low power device, operates on a single supply, and has an internal oscillator and an external clocking option [1]. It is rated for operation from -55 C to +225 C with a maximum output current capability of 50 mA. The amplifier chip is designed as a 14-pin, hermetically-sealed device in a ceramic package. Table I shows some of the device manufacturer s specifications.

Patterson, Richard↗

NASA NTRS2018

Nanoengineered Materials for SWIR HOT Detectors

Heavy metal Selenide has been investigated for more than half century for high operating temperature (HOT) mid wave infrared (MWIR) applications. Most of the efforts have been devoted to make detector arrays on high-resistivity Si substrates for operating wavelengths in the 1.5 to 5.0 m region using physical vapor transport grown poly crystalline materials. For most of the biological spectral and imaging applications, short wave infrared (SWIR) detectors have shown better performance. Recent growth materials have shown variation in morphology with slight change in growth conditions and hence variation in performance parameters such as bandgap, mobility and resistivity from sample to sample. We have performed growth and optical characterization of pure and doped PbS and PbSe and have determined bandgap using available theoretical models for different morphologies.

Singh, N. B.↗

NASA NTRS2009

Assessment of SOI AND Gate, Type CHT-7408, for Operation in Extreme Temperature Environments

Electronic parts based on silicon-on-insulator (SOI) technology are finding widespread applications due to their ability to operate in harsh environments and the benefits they offer as compared to their silicon counterparts. Due to their construction, they are tailored for high temperature operation and show good tolerance to radiation events. In addition, their inherent design lessens the formation of parasitic junctions, thereby reducing leakage currents, decreasing power consumption, and enhancing speed. These devices are typically rated in temperature capability from -55 C to about +225 C, and their characteristics over this temperature range are documented in data sheets. Since electronics in some of NASA space exploration missions are required to operate under extreme temperature conditions, both cold and hot, their characteristic behavior within the full temperature spectrum must be determined to establish suitability for use in space applications. The effects of extreme temperature exposure on the performance of a new commercial-off-the-shelf (COTS) SOI AND gate device were evaluated in this work. The high temperature, quad 2-inputs AND gate device, which was recently introduced by CISSOID, is fabricated using a CMOS SOI process. Some of the specifications of the CHT-7408 chip are listed in a table. By supplying a constant DC voltage to one gate input and a 10 kHz square wave into the other associated gate input, the chip was evaluated in terms of output response, output rise (t(sub r)) and fall times (tf), and propagation delays (using a 50% level between input and output during low to high (tPLH) and high to low (tPHL) transitions). The supply current of the gate circuit was also obtained. These parameters were recorded at various test temperatures between -195 C and +250 C using a Sun Systems environmental chamber programmed at a temperature rate of change of 10 C/min. In addition, the effects of thermal cycling on this chip were determined by exposing it to a total of 12 cycles between -195 C and +250 C. Following the cycling activity, measurements were performed again at the test temperatures of -195 C, +21 C, and +250 C.

Patterson, Richard↗

NASA NTRS1993

Nuclear concepts/propulsion

Nuclear thermal and nuclear electric propulsion systems will enable and/or enhance important space exploration missions to the moon and Mars. Current efforts are addressing certain research areas, although NASA and DOE still have much work yet to do. Relative to chemical systems, nuclear thermal propulsion offers the potential of reduced vehicle weight, wider launch windows. and shorter transit times, even without aerobrakes. This would improve crew safety by reducing their exposure to cosmic radiation. Advanced materials and structures will be an important resource in responding to the challenges posed by safety and test facility requirements, environmental concerns, high temperature fuels and the high radiation, hot hydrogen environment within nuclear thermal propulsion systems. Nuclear electric propulsion (NEP) has its own distinct set of advantages relative to chemical systems. These include low resupply mass, the availability of large amounts of onboard electric power for other uses besides propulsion, improved launch windows, and the ability to share technology with surface power systems. Development efforts for NEP reactors will emphasize long life operation of compact designs. This will require designs that provide high fuel burnup and high temperature operation along with personnel and environmental safety.

Miller, Thomas J.↗

NASA NTRS1984

High Curie temperature drive layer materials for ion-implanted magnetic bubble devices

Ion implantation of bubble garnets can lower the Curie temperature by 70 C or more, thus limiting high temperature operation of devices with ion-implanted propagation patterns. Therefore, double-layer materials were made with a conventional 2-micron bubble storage layer capped by an ion-implantable drive layer of high Curie temperature, high magnetostriction material. Contiguous disk test patterns were implanted with varying doses of a typical triple implant. Quality of propagation was judged by quasistatic tests on 8-micron period major and minor loops. Variations of magnetization, uniaxial anisotropy, implant dose, and magnetostriction were investigated to ensure optimum flux matching, good charged wall coupling, and wide operating margins. The most successful drive layer compositions were in the systems (SmDyLuCa)3(FeSi)5O12 and (BiGdTmCa)3(FeSi)5O12 and had Curie temperatures 25-44 C higher than the storage layers.

Fratello, V. J.↗

NASA NTRS2020

Additive Manufacture of Refractory Alloy C103 for Propulsion Applications

C103 is niobium alloy used in high temperature operating environments. Traditional manufacture methods suffer from feedstock constraints, difficult to machine, high buy-to-fly ratios, and high costs resulting in a limited number of suppliers. Additive manufacture (AM) offers advantages in production of complex parts, improved properties, reproducibility, with significant material cost and schedule savings. The objectives of this project was to investigate the feasibility to AM C103, develop powder feedstock, optimize process parameters, establish design criteria, investigate post-process heat treatments, and determine material properties. AM C103 proved feasible, increased design flexibility, improved mechanical properties compared to wrought, and resulted in an order of magnitude cost reduction.

Omar R Mireles↗

NASA NTRSDate not supplied

Additive Manufacture of Refractory Alloy C103 for Propulsion Applications

Omar Roberto Mireles↗

NASA NTRS1981

The Conference on High Temperature Electronics

The status of and directions for high temperature electronics research and development were evaluated. Major objectives were to (1) identify common user needs; (2) put into perspective the directions for future work; and (3) address the problem of bringing to practical fruition the results of these efforts. More than half of the presentations dealt with materials and devices, rather than circuits and systems. Conference session titles and an example of a paper presented in each session are (1) User requirements: High temperature electronics applications in space explorations; (2) Devices: Passive components for high temperature operation; (3) Circuits and systems: Process characteristics and design methods for a 300 degree QUAD or AMP; and (4) Packaging: Presently available energy supply for high temperature environment.

Hamilton, D. J.↗

NASA NTRS2007

Lightweight, Flexible Solar Cells on Stainless Steel Foil and Polymer for Space and Stratospheric Applications

The availability of low-cost, lightweight and reliable photovoltaic (PV) modules is an important component in reducing the cost of satellites and spacecraft. In addition, future high-power spacecraft will require lightweight PV arrays with reduced stowage volume. In terms of the requirements for low mass, reduced stowage volume, and the harsh space environment, thin film amorphous silicon (a-Si) alloy cells have several advantages over other material technologies (1). The deposition process is relatively simple, inexpensive, and applicable to large area, lightweight, flexible substrates. The temperature coefficient has been found to be between -0.2 and -0.3 %/degC for high-efficiency triple-junction a-Si alloy cells, which is superior for high temperature operation compared to crystalline Si and triple-junction GaAs/InGaP/Ge devices at 0.53 %/degC and 0.45 %/degC, respectively (2). As a result, the reduction in efficiency at high temperature typical in space conditions is less for a-Si alloy cells than for their crystalline counterparts. Additionally, the a-Si alloy cells are relatively insensitive to electron and proton bombardment. We have shown that defects that are created by electrons with energies between 0.2 to 2 MeV with fluence up to 1x10(exp 15) e/sq cm and by protons with energy in the range 0.3 MeV to 5 MeV with fluence up to 1x10(exp 13) p/sq cm can be annealed out at 70 C in less than 50 hours (1). Further, modules incorporating United Solar s a-Si alloy cells have been tested on the MIR space station for 19 months with only minimal degradation (3). For stratospheric applications, such as the high altitude airship, the required PV arrays are typically of considerably higher power than current space arrays. Airships typically have a large area available for the PV, but weight is of critical importance. As a result, low cost and high specific power (W/kg) are key factors for airship PV arrays. Again, thin-film a-Si alloy solar cell technology is well suited to such applications.

Beernink, Kevin↗

NASA NTRS2015

Lightweight Damage Tolerant, High-Temperature Radiators for Nuclear Power and Propulsion

NASA is increasingly emphasizing exploration to bodies beyond near-Earth orbit. New propulsion systems and new spacecraft are being built for these missions. As the target bodies get further out from Earth, high energy density systems, e.g., nuclear fusion, for propulsion and power will be advantageous. The mass and size of these systems, including supporting systems such as the heat exchange system, including thermal radiators, will need to be as small as possible. Conventional heat exchange systems are a significant portion of the total thermal management mass and size. Nuclear electric propulsion (NEP) is a promising option for high-speed, in-space travel due to the high energy density of nuclear fission power sources and efficient electric thrusters. Heat from the reactor is converted to power for use in propulsion or for system power. The heat not used in the power conversion is then radiated to space as shown in figure 1. Advanced power conversion technologies will require high operating temperatures and would benefit from lightweight radiator materials. Radiator performance dictates power output for nuclear electric propulsion systems. Pitch-based carbon fiber materials have the potential to offer significant improvements in operating temperature, thermal conductivity, and mass. These properties combine to allow significant decreases in the total mass of the radiators and significant increases in the operating temperature of the fins. A Center-funded project at NASA Marshall Space Flight Center has shown that high thermal conductivity, woven carbon fiber fins with no matrix material, can be used to dissipate waste heat from NEP systems and because of high specific power (kW/kg), will require less mass and possibly less total area than standard metal and composite radiator fins for radiating the same amount of heat. This project uses an innovative approach to reduce the mass and size required for the thermal radiators to the point that in-space NEP and power is enabled. High thermal conductivity carbon fibers are lightweight, damage tolerant, and can be heated to high temperature. Areal densities in the NASA set target range of 2 to 4 kg/m2 (for enabling NEP) are achieved and with specific powers (kW/kg) a factor of about 7 greater than conventional metal fins and about 1.5 greater than carbon composite fins. Figure 2 shows one fin under test. All tests were done under vacuum conditions.

Craven, Paul D.↗

NASA NTRS1990

Combustion interaction with radiation-cooled chambers

Over 15 hours of thruster operation at temperatures between 1916 and 2246 C without failure or erosion has been demonstrated using iridium-coated rhenium chamber materials with nitrogen tetroxide/monomethylhydrazine propellants operating over a mixture ratio range of 1.60-2.05. Research is now under way to provide a basic understanding of the mechanisms which make high-temperature operation possible and to extend the capability to a wider range of conditions, including other propellant combinations and chamber materials. Techniques have been demonstrated for studying surface fracture phenomena. These include surface Raman and Auger for study of oxide formation, surface Raman and X-ray diffraction to determine the oxide phase, Auger to study oxide stoichiometry, and sputter Auger to study interdiffusion of alloy species.

Rosenberg, S. D.↗

NASA NTRSDate not supplied

Development of a Venus Surface Wind Sensor

To better understand the atmospheric structure and dynamics on the Venus surface and provide input to climate models, there is a need to measure the wind velocity and direction on the surface and track changes over extended periods. A wind sensor based on a miniature drag-force anemometer is being developed to meet the challenges for wind measurements and operational requirements on the surface of Venus. The sensor materials are chosen to enhance durability and prevent reactivity with the Venus surface atmosphere. Advantages of this approach include that it is independent of variable heat transfer, has been matured in other harsh environment applications, and has a low mass and power requirement. Prototype drag-force anemometers were demonstrated, integrated with a high-temperature operational amplifier, recording transient effects in a simulated Venus surface environment. For multidirectional wind monitoring, the sensors are small enough to be deployed orthogonally as a three-dimensional array on a small arm or mast. This presentation describes the development and demonstration of this miniature drag-force anemometer integrated with high temperature electronics in a simulated Venus surface environment.

wind measurement↗

NASA NTRS2005

Development of GaN-based microchemical sensor nodes

Sensors based III-N technology are gaining significant interest due to their potential for monolithic integration of RF transceivers and light sources and the capability of high temperature operations. We are developing a GaN-based micro chemical sensor node for remote detection of chemical toxins, and present electrical responses of AlGaN/GaN HEMT (High Electron Mobility Transistor) sensors to chemical toxins as well as other common gases.

extreme environment↗

NASA NTRS2005

Development of GaN-based micro chemical sensor nodes

Sensors based on III-N technology are gaining significant interest due to their potential for monolithic integration of RF transceivers and light sources and the capability of high temperature operations. We are developing a GaN-based micro chemical sensor node for remote detection of chemical toxins, and present electrical responses of AlGaN/GaN HEMT (High Electron Mobility Transistor) sensors to chemical toxins as well as other common gases.

chemical↗

NASA NTRS1977

Single heterostructure lasers of PbS/1-x/Se/x/ and Pb/1-x/Sn/x/Se with wide tunability

Single-heterostructure diode lasers formed by compositional interdiffusion (CID) and liquid-phase epitaxy (LPE) of lead salts are discussed. The CID technique, which involves creation of a single heterostructure in a pseudobinary compound having binary constituents with different vapor pressures, is reviewed; growth of lead-salt crystals of various compositions is described. Some electrical and optical characteristics, including properties indicative of high internal quantum efficiencies, are given for lasers which employ the CID and LPE diodes. High operating temperatures (i.e., liquid nitrogen levels and above), together with wide tuning ranges (a diode wavelength of 12.7 microns is reported), make the lasers useful in high-resolution spectrometry and advanced trace-gas monitoring systems.

Linden, K. J.↗

NASA NTRS1999

Stirling Space Engine Program: Final Report - Volume 1

The objective of this program was to develop the technology necessary for operating Stirling power converters in a space environment and to demonstrate this technology in full-scale engine tests. Hardware development focused on the Component Test Power Converter (CTPC), a single cylinder, 12.5-kWe engine. Design parameters for the CTPC were 150 bar operating pressure, 70 Hz frequency, and hot-and cold-end temperatures of 1050 K and 525 K, respectively. The CTPC was also designed for integration with an annular sodium heat pipe at the hot end, which incorporated a unique "Starfish" heater head that eliminated highly stressed brazed or weld joints exposed to liquid metal and used a shaped-tubed electrochemical milling process to achieve precise positional tolerances. Selection of materials that could withstand high operating temperatures with long life were another focus. Significant progress was made in the heater head (Udimet 700 and Inconel 718 and a sodium-filled heat pipe); the alternator (polyimide-coated wire with polyimide adhesive between turns and a polyimide-impregnated fiberglass overwrap and samarium cobalt magnets); and the hydrostatic gas bearings (carbon graphite and aluminum oxide for wear couple surfaces). Tests on the CTPC were performed in three phases: cold end testing (525 K), engine testing with slot radiant heaters, and integrated heat pipe engine system testing. Each test phase was successful, with the integrated engine system demonstrating a power level of 12.5 kWe and an overall efficiency of 22 percent in its maiden test. A 1500-hour endurance test was then successfully completed. These results indicate the significant achievements made by this program that demonstrate the viability of Stirling engine technology for space applications.

Dhar, Manmohan↗

NASA NTRS2003

Scandia-and-Yttria-Stabilized Zirconia for Thermal Barriers

yttria in suitable proportions has shown promise of being a superior thermal- barrier coating (TBC) material, relative to zirconia stabilized with yttria only. More specifically, a range of compositions in the zirconia/scandia/yttria material system has been found to afford increased resistance to deleterious phase transformations at temperatures high enough to cause deterioration of yttria-stabilized zirconia. Yttria-stabilized zirconia TBCs have been applied to metallic substrates in gas turbine and jet engines to protect the substrates against high operating temperatures. These coatings have porous and microcracked structures, which can accommodate strains induced by thermal-expansion mismatch and thermal shock. The longevity of such a coating depends upon yttria as a stabilizing additive that helps to maintain the zirconia in an yttria-rich, socalled non-transformable tetragonal crystallographic phase, thus preventing transformation to the monoclinic phase with an associated deleterious volume change. However, at a temperature greater than about 1,200 C, there is sufficient atomic mobility that the equilibrium, transformable zirconia phase is formed. Upon subsequent cooling, this phase transforms to the monoclinic phase, with an associated volume change that adversely affects the integrity of the coating. Recently, scandia was identified as a stabilizer that could be used instead of, or in addition to, yttria. Of particular interest are scandia-and-yttria-stabilized zirconia (SYSZ) compositions of about 6 mole percent scandia and 1 mole percent yttria, which have been found to exhibit remarkable phase stability at a temperature of 1,400 C in simple aging tests. Unfortunately, scandia is expensive, so that the problem becomes one of determining whether there are compositions with smaller proportions of scandia that afford the required high-temperature stability. In an attempt to solve this problem, experiments were performed on specimens made with reduced proportions of scandia. The criterion used to judge these specimens was whether they retained the non-transformable tetragonal phase after a severe heat treatment of 140 hours at 1,400 C.

Mess, Derek↗