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Physics of the Cosmos Program Annual Technology Report

What's in this Report? What's New? This fifth Program Annual Technology Report (PATR) summarizes the Programs technology development activities for fiscal year (FY) 2015. The PATR serves four purposes.1. Summarize the technology gaps identified by the astrophysics community;2. Present the results of this years technology gap prioritization by the PCOS Technology Management Board (TMB);3. Report on newly funded PCOS Strategic Astrophysics Technology (SAT) projects; and4. Detail progress, current status, and activities planned for the coming year for all technologies supported by PCOS Supporting Research and Technology (SRT) funding in FY 2015. .

PCOS↗

NASA Goddard Thermal Technology Overview 2016

This presentation summarizes the current plans and efforts at NASA Goddard to develop new thermal control technology for anticipated future missions. It will also address some of the programmatic developments currently underway at NASA, especially with respect to the NASA Technology Development Program. The effects of the recently enacted FY 16 NASA budget, which includes a sizeable increase, will also be addressed. While funding for basic technology development is still tight, significant efforts are being made in direct support of flight programs. Thermal technology implementation on current flight programs will be reviewed, and the recent push for Cube-sat mission development will also be addressed. Many of these technologies also have broad applicability to DOD, DOE, and commercial programs. Partnerships have been developed with the Air Force, Navy, and various universities to promote technology development. In addition, technology development activities supported by internal research and development (IRAD) program and the Small Business Innovative Research (SBIR) program are reviewed in this presentation. Specific technologies addressed include; two-phase systems applications and issues on NASA missions, latest developments of electro-hydrodynamically pumped systems, Atomic Layer Deposition (ALD), Micro-scale Heat Transfer, and various other research activities.

Thermal Vacuum Testing↗

NASA Goddard Thermal Technology Overview 2017

This presentation summarizes the current plans and efforts at NASA Goddard to develop new thermal control technology for anticipated future missions. It will also address some of the programmatic developments currently underway at NASA, especially with respect to the NASA Technology Development Program. The effects of the recently enacted FY 17 NASA budget, which includes a sizeable increase, will also be addressed. While funding for basic technology development is still tight, significant efforts are being made in direct support of flight programs. Thermal technology Implementation on current flight programs will be reviewed, and the recent push for CubeSat mission development will also be addressed. Many of these technologies also have broad applicability to DOD (Dept. of Defense), DOE (Dept. of the Environment), and commercial programs. Partnerships have been developed with the Air Force, Navy, and various universities to promote technology development. In addition, technology development activities supported by internal research and development (IRAD) program and the Small Business Innovative Research (SBIR) program are reviewed in this presentation. Specific technologies addressed include; two-phase systems applications and issues on NASA missions, latest developments of electro-hydrodynamically pumped systems, Atomic Layer Deposition (ALD), Micro-scale Heat Transfer, and various other research activities.

thermal vacuum testing↗

The Large UV/Optical/Infrared Surveyor (LUVOIR): Decadal Mission Concept Technology Development Overview

The Large Ultraviolet / Optical / Infrared (LUVOIR) Surveyor is one of four large mission concept studies being developed by NASA for consideration in the 2020 Astrophysics Decadal Survey. LUVOIR will support a broad range of science objectives, including the direct imaging and spectral characterization of habitable exoplanets around sun-like stars, the study of galaxy formation and evolution, the epoch of reionization, star and planet formation, and the remote sensing of Solar System bodies. The LUVOIR Science and Technology Definition Team (STDT) has tasked a Technology Working Group (TWG), with more than 60 members from NASA centers, academia, industry, and international partners, with identifying technologies that enable or enhance the LUVOIR science mission. The TWG has identified such technologies in the areas of Coronagraphy, Ultra-Stable Opto-mechanical Systems, Detectors, Coatings, Starshades, and Instrument Components, and has completed a detailed assessment of the state-of-the-art. We present here a summary of this technology assessment effort, as well as the current progress in defining a technology development plan to mature these technologies to the required technology readiness level (TRL).

Decadal Study; Technology; LUVOIR↗

NASA Goddard Thermal Technology Overview 2018

This presentation summarizes the current plans and efforts at NASA/Goddard to develop new thermal control technology for anticipated future missions. It will also address some of the programmatic developments currently underway at NASA, especially with respect to the NASA Technology Development Program. The effects of the recently submitted NASA budget will also be addressed. While funding for basic technology development is still tight, significant efforts are being made in direct support of flight programs. Thermal technology Implementation on current flight programs will be reviewed, and the recent push for Cube-sat mission development will also be addressed. Many of these technologies also have broad applicability to DOD, DOE, and commercial programs. Partnerships have been developed with the Air Force, Navy, and various universities to promote technology development. In addition, technology development activities supported by internal research and development (IRAD) program and the Small Business Innovative Research (SBIR) program are reviewed in this presentation. Specific technologies addressed include; two-phase systems applications and issues on NASA missions, latest developments of thermal control coatings, Atomic Layer Deposition (ALD), Micro-scale Heat Transfer, and various other research activities.

Thermal Vacuum Testing↗

Exploration Technologies for Operations

Although the International Space Station (ISS) assembly has been completed, the Operations support teams continue to seek more efficient and effective ways to prepare for and conduct the ISS operations and future exploration missions beyond low earth orbit. This search for improvement has led to a significant collaboration between the NASA research and advanced software development community at NASA Ames Research Center and the Mission Operations community at NASA Johnson Space Center. Since 2001, NASA Ames Research Center has been developing and applying its advanced intelligent systems and human systems integration research to mission operations tools for several of the unmanned Mars missions operations. Since 2006, NASA Ames Research Center has also been developing and applying its advanced intelligent systems and human systems integration research to mission operations tools for manned operations support with the Mission Operations Directorate at NASA Johnson Space Center. This paper discusses the completion of the development and deployment of a variety of intelligent and human systems technologies adopted for manned mission operations. The technologies associated with the projects include advanced software systems for operations and human-centered computing. Human-centered computing looks to the processes and procedures that people do to perform any given job, then attempts to identify opportunities to improve these processes and procedures. In particular, for mission operations, improvements are quantified by specifically identifying how a tool can increase a persons efficiency, enhance a persons functional capability, andor improve the assurance of a persons decisions. The Ames development team has collaborated with the Mission Operations team to identify areas of efficiencies through technology infusion applications in support of the Plan, Train, and Fly activities of human-spaceflight mission operations. The specific applications discussed in this paper are in the areas of mission planning systems, mission operations design modeling and workflow automation, advanced systems monitoring, mission control technologies, search tools, training management tools, spacecraft solar array management, spacecraft power management, and spacecraft attitude planning. We discuss these specific projects between the Ames Research Center and the Johnson Space Centers Mission Operations Directorate, and how these technologies and projects are enhancing the mission operations support for the International Space Station. We also discuss the challenges, problems, and successes associated with long-distance and multi-year development projects between the research team at Ames and the Mission Operations customers at Johnson Space center. Finally, we discuss how these technology infusion applications and underlying technologies might be used in the future to support on-board operations of the crew and spacecraft systems as human exploration expands beyond low earth orbit to destinations in the solar system where communications delays will require more on-board autonomy and planning by the crew. Longer communications delays will require that the ground mission operations support will be primarily strategic in nature, while the tactical level of planning, systems monitoring and control, and failure analysisisolationrecovery will be the responsibility of both the spacecraft autonomous systems and the crew. Our expectation is that the technologies

mission operations↗

Air Traffic Management Technology Demonstration 1 (ATD-1) Tech Transfer Document Summary: Version 3.0

This document summarizes transfer of NASA's terminal sequencing and spacing (TSS) and interval management (IM) technologies to the FAA (Federal Aviation Administration), as part of its Air Traffic Management Technology (ATM) Demonstration 1 activity. This activity, referred to as ATD-1, is part of NASA's Airspace Systems Program (ASP) specifically, its System Analysis, Integration, and Evaluation (SAIE) Project. ATD-1 is a multi-year research and development effort aimed at accelerating implementation and deployment of NASA-developed ATM technologies by the FAA. These technologies are designed to improve the utilization of Performance-Based Navigation (PBN) procedures inside congested terminal airspace. In terms of NASA's Technology Readiness Levels (TRLs), ATD-1 is focused on maturing its associated technologies from the Technology Development stage (TRL 4) to the Technology Demonstration stage (TRL 6). In order to ensure that the products of this tech-transfer are relevant and useful, NASA has created strong partnerships with the FAA and key industry stakeholders.

Technology transfer↗

Solar System Exploration Technology Requirements and Planning Process

The NASA Office of Space Science, in alliance with the Office of Advanced Concepts and Technology, has developed an Integrated Technology Strategy to guide its investment in technology for space science missions. This strategy establishes goals and strategic objectives that ensure that NASA and the nation derive the greatest possible scientific and economic benefits from investments in space science missions and technologies. Within the Office of Space Science, the Solar System Exploration Division in collaboration with the Office of Space Access and Technology, is developing a Technology Plan to implement these goals and to identify specific goals and to identify specific technology needs for solar system missions. This paper describes the philosophy, processes, and preliminary results of the systematic process being established for the identification and prioritization of solar system exploration technology needs.

space↗

Utilizing Gaps and Key Performance Parameters to Inform NASA Environmental Control and Life Support Capability Technology Decisions

Human spaceflight is a complex endeavor requiring multiple capabilities for transportation, crew health, scientific goals, and safe return to Earth. The difference between spaceflight proven capabilities and those needed for future exploration architectures is defined as a capability gap. Capability gaps are not technology specific. Each capability gap may be closed with a wide array of technologies that have unique benefits and challenges. Determining what a capability’s relevant and distinguishing key performance parameters (KPPs) are for a mission is critical. Mass, power, and volume are always constrained and important, but defining these in a way normalized by performance is very important. KPP definition for reliability, dormancy, and integration needs are hard to define but critical. Outside of technical considerations, the programmatic factors of the estimated time to develop the technology vs when a mission element is also a strong consideration in which technologies should be pursued. The Environmental Control and Life Support (ECLSS) capability areas include: life support, environmental monitoring, fire safety, and logistics. These capability areas are decomposed to high level gaps. While KPPs should be technology agnostic, they can be used to both compare technologies and measure progress of technology development over time. KPPs help define when the gap is closed, and the core mission objectives can be accomplished. Proposed technology improvements to enhance a capability should balance improved KPPs and against investments in other capabilities that are not yet closed. A selection of ECLSS gaps and KPPs and their formulation, current state, and how they inform capability roadmap planning are discussed.

Life Support↗

Moon-to-Mars Planetary Autonomous Construction Technology: MMPACT Material Screening

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. MMPACT must screen for the most feasible technologies with the earliest potential technology insertions given the ambitious goals of the Artemis campaign. This poster summarizes recent efforts to discover and document mechanical and thermal capabilities of various technologies: a laser-based vitreous material transformation from Texas-based ICON, a molten extrusion process from ICON, a mortar from MSFC, a mortar from an MSFC-Louisiana State University partnership, and a geopolymer from a MSFC-Pennsylvania State University partnership. Other testing and development activities are documented as well. [1] https://www.nasa.gov/directorates/spacetech/Lunar_Surface_Innovation_Initiative

In-situ Resource Utilization↗

ISS Technology Demonstrations for Future Spaceflight Medical Systems

Throughout the history of human spaceflight, crewmembers have experienced various in-flight medical conditions including illness and injury. Planned missions to the Moon and Mars will require capabilities to maintain the health of future space travelers. Mass, power, and volume available in the vehicles and habitats for these missions will be severely constrained; resupply of resources will be limited or non-existent, as will opportunities for evacuation to Earth. Furthermore, ground-based support will be hampered by communication latencies and blackouts. These vehicle and mission constraints will necessitate a medical system that has been efficiently planned, providing on-board procedural guidance in addition to a variety of medical devices and consumable resources. Medical capabilities required for the diagnosis and treatment of potential medical conditions during future spaceflight missions may include real-time health monitoring, medical imaging, and biomarker analyses ( e.g., blood or urine). Terrestrial medicine shares these needs, thus many of these medical capabilities could likely be satisfied by Commercial-Off-The-Shelf (COTS) devices and methodologies; however, in some cases the unique space environment and increased mission duration will drive the need to modify technologies and the way care is provided. NASA’s Human Research Program (HRP) Exploration Medical Capability (ExMC) Element and Mars Campaign Office’s Exploration Medical Integrated Product Team (XMIPT) are working together to decrease medical risk during exploration missions. Flight-tested medical diagnostic and treatment technologies are necessary to effectively manage medical conditions relevant to exploration missions while meeting vehicle constraints, integrating with medical decision-support tools, and enabling increasingly Earth-independent operations. Several projects have leveraged the ISS as a testbed for exploration, including 1) i n- situ blood analysis, 2) medical inventory, 3) intravenous fluid generation, and 4) autonomous medical procedure guidance. Management of several in-flight medical conditions, such as bacterial and viral infections and acute radiation syndrome, is dramatically improved with ability to assess blood cell populations, electrolytes, and metabolites. I n December 2020 and January 2021 ExMC performed an ISS technology demonstration (Tech Demo) of the HemoCue® WBC DIFF analyzer (HemoCue, Brea, CA), a COTS device that was modified to enable functionality in a spaceflight environment. This Tech Demo marked the first time that hematology measurements were successfully performed real-time in microgravity. Also modified and demonstrated was the reusable Handheld Electrolytes and Lab Technology for Humans (rHEALTH) ONE analyzer (rHEALTH, Bedford, MA), which uses flow cytometry and sheath-based hydrodynamic focusing methodologies. The rHEALTH ONE ISS Tech Demo in May 2022 demonstrated test results obtained in-flight matched those on the ground. NASA currently relies on crew self-reporting to manage and maintain medical inventory on ISS.The ability to maintain an accurate inventory becomes more critical during long duration missions since the crew will need to be increasingly autonomous in finding and utilizing medical items, including those scenarios when alternative treatments need to be considered due to limited or no resupply. HRP’s Medical Consumables Tracking (MCT) project was developed by ZIN Technologies, Inc. (Cleveland, OH), and demonstrated real-time tracking of medical supplies aboard the ISS between December 2016 and July 2018. The MCT system design utilized Radio Frequency Identification Device (RFID) technology to perform automated inventory and was installed in the Crew Health Care System (CHeCS) Resupply Stowage Rack (RSR). The challenge of limited shelf life, exacerbated by the lack of resupply opportunities, affects a plethora of medical system components including consumables, pharmaceuticals, and intravenous (IV) fluid. In 2010, ExMC funded ZIN Technologies, Inc. (Cleveland, OH), to develop the Intravenous Fluid Generation (IVGEN) system. IV fluids were successfully generated with IVGEN using the potable water supply on ISS during ISS Expedition 23. The XMIPT is in the process of developing a miniaturized version of the original IVGEN hardware for a future Tech Demo aboard the ISS. Current ISS medical operations rely heavily on preflight training and real-time remote guidance, both of which become impractical or impossible for exploration missions. The primary goal of the Autonomous Medical Officer Support (AMOS) Software Tech Demos on ISS was to confirm telemedical proof-of-concept for autonomous medical imaging in an operational setting. This novel software tool shifts emphasis from preflight training and real-time remote guidance to in-flight just-in-time instruction, a new and necessary paradigm for crew medical autonomy. AMOS introduces a novel, streamlined skill management concept for exploration missions featuring comprehensive training and guidance modules for ultrasound examinations using the ISS Ultrasound 2 (a modified GE Vivid-q™; General Electric HealthCare, Chicago, IL). With no prior crew training or remote guidance, two Tech Demos on the ISS (April 2020 and June 2022) resulted in high quality, clinically useful image sets. We will provide a review of historical, current, and planned medical devices and technologies considered for inclusion within future spaceflight medical systems and summarize hardware development activities and medical device tech demos conducted on the ISS.

Astronaut health and performance↗

OAST Technology for the Future. Executive Summary

NASA's Office of Aeronautics and Space Technology (OAST) conducted a workshop on the In-Space Technology Experiments Program (IN-STEP) December 6-9, 1988, in Atlanta, Georgia. The purpose of this workshop was to identify and prioritize space technologies which are critical for future national space programs and which require validation in the space environment. A secondary objective was to review the current NASA (In-Reach) and Industry/University (Out-Reach) experiments. Finally, the aerospace community was requested to review and comment on the proposed plans for the continuation of the In-Space Technology Experiments Program. In particular, the review included the proposed process for focusing the next experiment selection on specific, critical technologies and the process for implementing the hardware development and integration on the Space Shuttle vehicle. The product of the workshop was a prioritized listing of the critical space technology needs in each of eight technology disciplines. These listings were the cumulative recommendations of nearly 400 participants, which included researchers, technologists, and managers from aerospace industries, universities, and government organizations.

BMDO COLLECTION↗

A Fast Technology Infusion Model for Aerospace Organizations

A multi-year Fast Technology Infusion initiative proposes a model for aerospace organizations to improve the cost-effectiveness by which they mature new, in-house developed software and hardware technologies for space mission use. The first year task under the umbrella of this initiative will provide the framework to demonstrate and document the fast infusion process. The viability of this approach will be demonstrated on two technologies developed in prior years with internal Jet Propulsion Laboratory (JPL) funding. One hardware technology and one software technology were selected for maturation within one calendar year or less. The overall objective is to achieve cost and time savings in the qualification of technologies. At the end of the recommended three-year effort, we will have demonstrated for six or more in-house developed technologies a clear path to insertion using a documented process that permits adaptation to a broad range of hardware and software projects.

technology readiness level↗

Innovation in complementary energy technologies from renewable energy policies

Complementary renewable technologies support renewable energy use as they can help balance the intermittency of solar and wind generation. Previous research has shown that environmental policies directly targeting renewable energy can drive innovation in solar PV and wind technology. This study explores the impact of renewable policies on innovation in complementary renewable technology that assists with integration, including combustion with mitigation potential, efficient power transmission or distribution, and enabling technologies. We use negative binomial models and a panel of 25 OECD countries from 1997 to 2015 to evaluate these relationships. We are not able to find evidence that renewable policies incentivize innovation in complementary combustion or transmission and distribution technologies, and only limited evidence that demand-pull instruments are associated with increased innovation in smart grid technology. Technology-push policies, such as public research and development funds for renewable energy, have had limited impact on grid-supporting energy storage innovation. Our findings suggest that policymakers wishing to accelerate these complementary technologies need to go beyond policies targeting renewable energy in order to drive innovation in complementary fields.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Decarbonization and technology cost drivers: considerations for potential future thermoelectric water use in the power sector

The power sector is currently undergoing significant changes, driven by a combination of factors, including decarbonization and technology innovation. This study aims to assess implications of these drivers on U.S. power sector technology futures and the associated water and environmental implications for cooling thermoelectric power plants. Specifically, we evaluate four decarbonization scenarios for the contiguous United States that vary in assumptions concerning demand growth and technology costs, with technology costs driving alternative outcomes that prioritize either technologies that require low amounts of water (such as wind, solar, and battery) or high amounts of water (such as nuclear and carbon capture and storage). These scenarios are executed in a power sector capacity expansion model and compared to two reference scenarios that assume status quo with policy and cost drivers. Our analysis indicates that future U.S. thermoelectric water withdrawals could decrease by 25%–60%, but water consumption could more than triple in some scenarios. These changes are driven by a combination of retirement of some power facilities, shifts in cooling technologies, and new technology deployment. The water use patterns vary across the United States, with the eastern regions demonstrating a lot more variability in water consumption across scenarios than western regions. However, local concerns can influence these possible investments, since increased water consumption can exacerbate water scarcity, leading to conflicts among competing users and affecting regional social, environmental, and economic dynamics. Future work should consider possible costs associated with alternate water sources, as well as improve the representation of water constraints within simulations. Inclusion of extreme events and alternate modeling platforms (e.g. production cost modeling and resource adequacy) may also be warranted to further stress test the robustness of these possible technology futures. Such assessments will be critical for ensuring decarbonization and other infrastructure-oriented investments lead to a reliable and resilient power grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Retrofitting Holcim Ste. Genevieve Cement Plant with CO2 Capture Plant Using Air Liquide Cryocap™ FG Technology

The global cement manufacturing industry is a major contributor to carbon dioxide emissions. The International Energy Agency's "Net Zero Emissions by 2050 Scenario" identifies CCS as a major strategy for meeting that goal. This project is among the first attempts to transfer capture technology developed at coal-fired power plants to the cement industry. The main objective of the project is to execute and complete a front-end engineering and design (FEED) studies for commercial-scale, carbon capture projects that separates 95% of the total CO2 emissions at the Holcim (US) Ste. Genevieve cement manufacturing facility using Air Liquide’s Pressure Swing Adsorption system (PSA) assisted Cryocap™ technology. The Holcim Ste. Genevieve cement plant in Missouri, US, boasts one of the largest single cement production lines in the world, with a capacity of approximately 12,000 t/day. The plant currently uses traditional fuels, namely coal and petcoke. The captured CO2 will be pipeline and geological storage grade. The industrial host site emits approximately 3.0 million tonne CO2/yr. Air Liquide’s Cryocap™ technology has been developed over the last 18+ years for CO2 capture applications. It has been shown to be applicable to a variety of industrial applications (e.g., steel, cement, SMR, Fluidized Catalytic Crackers (FCCs)). Cryocap™ FG consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The project team is led by the Prairie Research Institute at the University of Illinois at Urbana-Champaign. The tasks include: complete FEED study for retrofitting the industrial facility with a carbon capture system to support developing a detailed cost estimate; business case analysis outlining the anticipated revenue and credits if projects was built and operated; technoeconomic analysis (TEA) outlining how capture system achieves DOE capture goals; and life cycle (LCA) analysis demonstrating zero net carbon emissions. The FEED study was successfully completed. This includes completing the process basis of design; preliminary engineering; outside battery limits (OSBL) detailed engineering including a Zero Liquid Discharge (ZLD) wastewater treatment system; inside battery limits (ISBL) detailed engineering [1]. An overall project capital cost estimate within a -20%/+30% accuracy was developed. The major contributors to the Total Plant Cost (TPC), by system, are the costs associated with the Outside Battery Limit (OSBL) section of the plant which includes a new river water intake structure and a Zero Liquid Discharge (ZLD) system. By cost category, the major contributors to the TPC are equipment and subcontractor costs, followed closely by engineering, construction management, home office and contractor fees. The TEA has been created to reflect the findings of the project. It analyzes the economic performance of the Cryocap™ technology by reviewing the estimated capital costs, operating cost, and revenue. The Cost of Capture (COC) associated with the Cryocap™ technology for 95% CO2 capture, when considering NETL 2018 economic assumptions (42/58 debt/equity ratio, 5.15% interest on debt and 1.42% return on equity in real dollars) and 2022 economic assumptions (42/58 debt/equity ratio, 8.82% interest on debt and 4.90% return on equity in real dollars) was found to be much lower than that for the DOE-NETL’s base-line cases. The highest contributors to the COC are annualized capital expenditures (CAPEX) and electricity consumption which can be offset by using lower cost renewable sources. The LCA was conducted using OpenLCA which is an open-source software that is recommended by NETL. The database utilized for this study was a modified version of TRACI 2.1 (developed by the US. Environmental Protection Agency’s National Risk Management Research Laboratory and modified by NETL). The Cryocap™ FG technology does not consume fuels in significant quantities and does not utilize specialized chemical solvents subject to decomposition, such as those utilized in amine-based carbon capture systems. The Cryocap™ FG technology mainly utilizes electricity as its energy input; hence, its calculated emissions are mainly associated with the generation of electricity offsite and are dependent on the energy matrix of the grid at the time of project implementation. The water consumption impact of the Cryocap™ FG is mostly for makeup of the water lost by evaporation in the cooling tower; however, the carbon capture plant will be equipped with a ZLD system to avoid effluent streams and minimize water consumption. The successful construction and operation of this plant based on this study results will provide a means to demonstrate an economically attractive and transformational capture technology that can be used to retrofit existing plants and be deployed at new plants.

01 COAL, LIGNITE, AND PEAT↗

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗

Proceedings from the State of the Science and Technology for Minimizing Impacts to Bats from Wind Energy

The U.S. Department of Energy Wind Energy Technologies Office (DOE WETO), and the National Renewable Energy Laboratory convened a workshop entitled the State of the Science and Technology for Minimizing Impacts to Bats from Wind Energy on 13–14 November 2019. The objectives of the workshop were to (1) Identify the current impact minimization measures that are, or can be, used to reduce bat fatalities at wind energy facilities, (2) Assess the current effectiveness of those minimization measures, (3) Identify and assess the research and development (R&D) opportunities needed to optimize and improve the effectiveness of current minimization and deterrent technologies and inform the development of future solutions; and (4) Identify potential emerging or novel methods for informing impact minimization measures at or around wind energy facilities. Specifically, the workshop focused on deterrent and curtailment strategies. For deterrents, the discussion centered on the existing technology (i.e., ultrasonic deterrents, dim-UV light, and texture coating), integration with wind turbines (either retrofitting or out of the box installation), effectiveness, validation studies, and cost (e.g., technology, installation, validation, and maintenance). For curtailment, the conversation was divided into blanket curtailment (i.e., based on time and wind speed) and smart curtailment (i.e., blanket curtailment plus additional variables such as temperature or bat activity). The workshop included plenary presentations, panels, and breakout sessions to share data and stakeholder perspectives, and engage participants. Although there are several priority topics related to bat and wind energy, this workshop focused the discussion on the current technologies and strategies that are, or can be, used to reduce bat fatalities at wind energy facilities, status of research and development (R&D) of minimization measures, opportunities to optimize costs and improve effectiveness, and potential emerging or novel approaches to explore. This workshop took a holistic approach and discussed all aspects associated with advancing deterrent technologies and curtailment strategies, including the technological, biological, economic, and regulatory barriers faced by the wind energy and wildlife community.

13 HYDRO ENERGY↗