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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

NASA welding assessment program

A long duration test was conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules were thermally cycled for 36,000 cycles between -80 and +80 C. The environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the earth's shadow was simulated. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived this extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

Stofel, E. J.↗
NASA NTRS1985

Interactions between large space power systems and low-Earth-orbit plasmas

There is a growing tendency to plan space missions that will incorporate very large space power systems. These space power systems must function in the space plasma environment, which can impose operational limitations. As the power output increases, the operating voltage also must increase and this voltage, exposed at solar array interconnects, interacts with the local plasma. The implications of such interactions are considered. The available laboratory data for biased array segment tests are reviewed to demonstrate the basic interactions considered. A data set for a floating high voltage array test was used to generate approximate relationships for positive and negative current collection from plasmas. These relationships were applied to a hypothetical 100 kW power system operating in a 400 km, near equatorial orbit. It was found that discharges from the negative regions of the array are the most probable limiting factor in array operation.

Stevens, N. J.↗
NASA NTRS1984

NASA welding assessment program

A long duration test has been conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules have been thermally cycled for 36,000 cycles between -80 and +80 C on this JPL and NASA Lewis Research Center sponsored work. This test simulates the environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the Earth's shadow. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived his extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

Stofel, E. J.↗
NASA NTRS1990

Rapid thermal cycling of new technology solar array blanket coupons

NASA Lewis Research Center is conducting thermal cycle testing of a new solar array blanket technologies. These technologies include test coupons for Space Station Freedom (SSF) and the advanced photovoltaic solar array (APSA). The objective of this testing is to demonstrate the durability or operational lifetime of the solar array interconnect design and blanket technology within a low earth orbit (LEO) or geosynchronous earth orbit (GEO) thermal cycling environment. Both the SSF and the APSA array survived all rapid thermal cycling with little or no degradation in peak performance. This testing includes an equivalent of 15 years in LEO for SSF test coupons and 30 years of GEO plus ten years of LEO for the APSA test coupon. It is concluded that both the parallel gap welding of the SSF interconnects and the soldering of the APSA interconnects are adequately designed to handle the thermal stresses of space environment temperature extremes.

Scheiman, David A.↗
NASA NTRS1993

Atomic oxygen interaction with spacecraft materials: Relationship between orbital and ground-based testing for materials certification

The effects of atomic oxygen on boron nitride (BN), silicon nitride (Si3N4), Intelsat 6 solar cell interconnects, organic polymers, and MoS2 and WS2 dry lubricant, were studied in Low Earth Orbit (LEO) flight experiments and in a ground based simulation facility. Both the inflight and ground based experiments employed in situ electrical resistance measurements to detect penetration of atomic oxygen through materials and Electron Spectroscopy for Chemical Analysis (ESCA) analysis to measure chemical composition changes. Results are given. The ground based results on the materials studied to date show good qualitative correlation with the LEO flight results, thus validating the simulation fidelity of the ground based facility in terms of reproducing LEO flight results. In addition it was demonstrated that ground based simulation is capable of performing more detailed experiments than orbital exposures can presently perform. This allows the development of a fundamental understanding of the mechanisms involved in the LEO environment degradation of materials.

Cross, Jon B.↗
NASA NTRS1984

Investigation of welded interconnection of large area wraparound contacted silicon solar cells

An investigation was conducted to evaluate the welding and temperature cycle testing of large area 5.9 x 5.9 wraparound silicon solar cells utilizing printed circuit substrates with SSC-155 interconnect copper metals and the LMSC Infrared Controlled weld station. An initial group of 5 welded modules containing Phase 2 developmental 5.9 x 5.9 cm cells were subjected to cyclical temperatures of + or 80 C at a rate of 120 cycles per day. Anomalies were noted in the adhesion of the cell contact metallization; therefore, 5 additional modules were fabricated and tested using available Phase I cells with demonstrated contact integrity. Cycling of the later module type through 12,000 cycles indicated the viability of this type of lightweight flexible array concept. This project demonstrated acceptable use of an alternate interconnect copper in combination with large area wraparound cells and emphasized the necessity to implement weld pull as opposed to solder pull procedures at the cell vendors for cells that will be interconnected by welding.

Lott, D. R.↗
NASA NTRS1986

Reliability models applicable to space telescope solar array assembly system

A complex system may consist of a number of subsystems with several components in series, parallel, or combination of both series and parallel. In order to predict how well the system will perform, it is necessary to know the reliabilities of the subsystems and the reliability of the whole system. The objective of the present study is to develop mathematical models of the reliability which are applicable to complex systems. The models are determined by assuming k failures out of n components in a subsystem. By taking k = 1 and k = n, these models reduce to parallel and series models; hence, the models can be specialized to parallel, series combination systems. The models are developed by assuming the failure rates of the components as functions of time and as such, can be applied to processes with or without aging effects. The reliability models are further specialized to Space Telescope Solar Arrray (STSA) System. The STSA consists of 20 identical solar panel assemblies (SPA's). The reliabilities of the SPA's are determined by the reliabilities of solar cell strings, interconnects, and diodes. The estimates of the reliability of the system for one to five years are calculated by using the reliability estimates of solar cells and interconnects given n ESA documents. Aging effects in relation to breaks in interconnects are discussed.

Patil, S. A.↗
NASA NTRS1980

Blanket technology workshop report

The solar array blanket, defined as a substrate covered with interconnected and glassed solar cells, but excluding the necessary support structure, deployment, and orientation devices is considered. The interactions between the blanket and the structure that is used to package, deploy, support and, if necessary restow it, are addressed along with systems constraints such as spacecraft configuration, size, and payload requirements. The influence on blanket design is emphasized. The three main mission classes considered are low Earth orbital (LEO), intermediate, or LEO to GEO transfer, and geosynchronous (GEO). Although interplanetary missions could be considered to be a separate class, their requirements, primarily power per unit mass, are generally close enough to geosynchronous missions to allow this mission class to be included within the third type. Examination of the critical elements of each class coupled with considerations of the shuttle capabilities is used to define the type of blanket technology most likely required to support missions that will be flown starting in 1990.

Scott-Monck, J. A.↗
NASA NTRS1981

Voltage gradients in solar array cavities as possible breakdown sites in spacecraft-charging-induced discharges

A possible explanation for environmentally-induced discharges on geosynchronous satellites exists in the electric fields formed in the cavities between solar cells - the small gaps formed by the cover slides, solar cells, metallic interconnects and insulating substrate. When exposed to a substorm environment, the cover slides become less negatively charged than the spacecraft ground. If the resultant electric field becomes large enough, then the interconnect could emit electrons (probably by field emission) which could be accelerated to space by the positive voltage on the covers. An experimental study was conducted using a small solar array segment in which the interconnect potential was controlled by a power supply while the cover slides were irradiated by monoenergetic electrons. It was found that discharges could be triggered when the interconnect potential became at least 500 volts negative with respect to the cover slides. Analytical modeling of satellites exposed to substorm environments indicates that such gradients are possible. Therefore, it appears that this trigger mechanism for discharges is possible.

Stevens, N. J.↗
NASA NTRS1981

Voltage gradients in solar array cavities as possible breakdown sites in spacecraft-charging-induced discharges

A possible explanation for environmentally-induced discharges on geosynchronous satellites exists in the electric fields formed in the cavities between solar cells - the small gaps formed by the cover slides, solar cells, metallic interconnects and insulating substrate. When exposed to a substorm environment, the cover slides become less negatively charged than the spacecraft ground. Hence, it is possible for metallic surfaces (usually silver mesh) to be at a negative potential in a cavity that has a 'positive' surface above it. If the resultant electric field becomes large enough, then the interconnect could emit electrons (probably by field emission) which could be accelerated to space by the positive voltage on the covers. An experimental study was connected using a small solar array segment in which the interconnect potential was controlled by a power supply while the cover slides were irridated by monoenergetic electrons. It was found that discharges could be triggered when the interconnect potential became at least 500 volts negative with respect to the cover slides. Analytical modeling of satellites exposed to substorm environments indicates that such gradients are possible. Therefore, it appears that this trigger mechanism for discharges is possible. Details of the experiment and modeling study are presented.

Stevens, N. J.↗
NASA NTRS1972

The 110 watt per kilogram lightweight solar array system

This ultralightweight solar array system is applied to three generic mission types: (1) interplanetary, (2) geosynchronous, and (3) manned space station. The requirements of each of these missions, as they pertain to the solar array, are presented. Existing lightweight solar array system concepts are reviewed, along with conclusions regarding the applicability of this technology to the feasibility of the ultralightweight solar array system. Several system concepts are included for further evaluation. The existing technology base, as it pertains to solar cells, solar cell covers, interconnects and substrates, and deployable booms, is reviewed. The attitude control of spacecraft with large flexible solar arrays is also discussed.

Shepard, N. F.↗
NASA NTRS1978

Center punched solar cell module development effort

The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.

Ross, R. E.↗
NASA NTRS1982

Tab Interconnect Work Station

Second work station along solar-array assembly line automatically attaches two interconnect tabs to each silicon solar cell. Machine feeds, forms, and cuts tabs from reel of pretinned metal ribbon, transfers tabs into position, and solders them to cell.

Garwood, G.↗
NASA NTRS1984

Ultrasonic Bonding of Solar-Cell Leads

Rolling ultrasonic spot-bonding method successfully joins aluminum interconnect fingers to silicon solar cells with copper metalization. Technique combines best features of ultrasonic rotary seam welding and ultrasonic spot bonding: allows fast bond cycles and high indexing speeds without use of solder or flux. Achieves reliable bonds at production rates without damage to solar cells. Bonding system of interest for all solar-cell assemblies and other assemblies using flat leads (rather than round wires).

Frasch, W.↗
NASA NTRS1976

Integral glass sheet encapsulation for terrestrial panel applications

Concepts for integral glass sheet encapsulation of terrestrial solar cell modules using techniques based upon electrostatic bonding are being developed. It is possible for the glass to provide hermetic encapsulation, the structural support, and a vehicle for integral interconnection of the solar cells. Anticipated capabilities, present status, and cost projections for large scale terrestrial utilization are discussed.

Minnucci, J. A.↗
NASA NTRS1971

The X-ray corona and the photospheric magnetic field.

Soft X-ray photographs of the solar corona have been obtained on four flights of a rocket-borne grazing incidence telescope having a resolution of a few arc sec. The configuration of the X-ray emitting structures in the corona has been compared to the magnetic field distribution measured by photospheric longitudinal magnetograms. The X-ray structures trace the three-dimensional configuration of the magnetic field through the lower corona. Active regions in the corona take the form of tubular structures connecting regions of opposite magnetic polarity within the same or adjacent chromospheric active regions. Higher, larger structures link widely separated active regions into complexes of activity covering substantial fractions of the disk. The complexes are separated by areas of low average field in the photosphere. Interconnections across the solar equator appear to originate over areas of preceding polarity.

Krieger, A. S.↗
NASA NTRS1982

Parrallel Connections Would Improve Array Reliability

Hexagonnally-close-packed round solar cells are interconnected in series strings. Parallel contacts between cells at equipotential in adjacent series strings insure redundant current paths to relieve adverse effects of cell failures and mismatches. Parallel connections carry no current if cells are matched and functioning normally. If cell fails, tabs carry current to bypass inoperative cell.

Crouthamel, M. S.↗