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DOE OSTI2023

Open‐source photovoltaic model pipeline validation against well‐characterized system data

Abstract All freely available plane‐of‐array (POA) transposition models and photovoltaic (PV) temperature and performance models in pvlib‐python and pvpltools‐python were examined against multiyear field data from Albuquerque, New Mexico. The data include different PV systems composed of crystalline silicon modules that vary in cell type, module construction, and materials. These systems have been characterized via IEC 61853‐1 and 61853‐2 testing, and the input data for each model were sourced from these system‐specific test results, rather than considering any generic input data (e.g., manufacturer's specification [spec] sheets or generic Panneau Solaire [PAN] files). Six POA transposition models, 7 temperature models, and 12 performance models are included in this comparative analysis. These freely available models were proven effective across many different types of technologies. The POA transposition models exhibited average normalized mean bias errors (NMBEs) within ±3%. Most PV temperature models underestimated temperature exhibiting mean and median residuals ranging from −6.5°C to 2.7°C; all temperature models saw a reduction in root mean square error when using transient assumptions over steady state. The performance models demonstrated similar behavior with a first and third interquartile NMBEs within ±4.2% and an overall average NMBE within ±2.3%. Although differences among models were observed at different times of the day/year, this study shows that the availability of system‐specific input data is more important than model selection. For example, using spec sheet or generic PAN file data with a complex PV performance model does not guarantee a better accuracy than a simpler PV performance model that uses system‐specific data.

14 SOLAR ENERGY↗

NASA NTRS1982

Progress on advanced dc and ac induction drives for electric vehicles

Progress is reported in the development of complete electric vehicle propulsion systems, and the results of tests on the Road Load Simulator of two such systems representative of advanced dc and ac drive technology are presented. One is the system used in the DOE's ETV-1 integrated test vehicle which consists of a shunt wound dc traction motor under microprocessor control using a transistorized controller. The motor drives the vehicle through a fixed ratio transmission. The second system uses an ac induction motor controlled by transistorized pulse width modulated inverter which drives through a two speed automatically shifted transmission. The inverter and transmission both operate under the control of a microprocessor. The characteristics of these systems are also compared with the propulsion system technology available in vehicles being manufactured at the inception of the DOE program and with an advanced, highly integrated propulsion system upon which technology development was recently initiated.

Schwartz, H. J.↗

NASA NTRS2005

Status of the International Space Station Regenerative ECLSS Water Recovery and Oxygen Generation Systems

NASA is developing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for deployment on the International Space Station (ISS). The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems International (HSSSI), Inc., while the UPA and PSM are developed in- house by the Marshall Space Flight Center (MSFC). The assemblies have completed the manufacturing phase and are in various stages of testing and integration into the flight racks. This paper summarizes the status as of April 2005 and describes some of the technical challenges encountered and lessons learned over the past year.

Bagdigian, Robert M.↗

NASA NTRS2000

Inflatable Structures Technology Handbook: Inflatable Habitats - Chapter 21

The technologies required to design, fabricate, and utilize an inflatable module for space applications has been demonstrated and proven by the TransHab team during the development phase of the program. Through testing and hands-on development several issues about inflatable space structures have been addressed , such as: ease of manufacturing, structural integrity, micrometeorite protection, folding , and vacuum deployment. The TransHab inflatable technology development program has proven that not only are inflatable structures a viable option, but they also offer significant advantages over conventional metallic structures.

Kennedy, Kriss J.↗

NASA NTRS2016

Atmospheric In-Situ Resource Utilization For Mars Application

NASA now looks to Mars as the next step in human space exploration. A couple of challenges of such a destination include affordability and weight/volume limitations. As a way to solve these issues NASA is looking into the practice of In-Situ Resource Utilization (ISRU). Instead of manufacturing and bringing all the supplies necessary for a Mars mission and return trip, the goal is to send a preliminary mission to produce reserves of propellant, water, and oxygen on site. Part of this effort includes the Atmospheric Processing Module (APM). The APM is part of a lander that is composed of multiple compartments, each having a unique function; regolith collection/processing, water processing, atmospheric processing, and product storage. The overall goal is to develop the capability to produce methane (CH4) and oxygen as a fuel/oxidizer combo via a Sabatier reaction using resources from the Martian environment. The APM still must undergo modifications in design, and perhaps method, to become flight-ready to produce methane at the level of purity and quantity needed for a vehicle.

isru↗

DOE OSTI2022

Expanding the use of ethanol as a feedstock for cell-free synthetic biochemistry by implementing acetyl-CoA and ATP generating pathways

Abstract Ethanol is a widely available carbon compound that can be increasingly produced with a net negative carbon balance. Carbon-negative ethanol might therefore provide a feedstock for building a wider range of sustainable chemicals. Here we show how ethanol can be converted with a cell free system into acetyl-CoA, a central precursor for myriad biochemicals, and how we can use the energy stored in ethanol to generate ATP, another key molecule important for powering biochemical pathways. The ATP generator produces acetone as a value-added side product. Our ATP generator reached titers of 27 ± 6 mM ATP and 59 ± 15 mM acetone with maximum ATP synthesis rate of 2.8 ± 0.6 mM/h and acetone of 7.8 ± 0.8 mM/h. We illustrated how the ATP generating module can power cell-free biochemical pathways by converting mevalonate into isoprenol at a titer of 12.5 ± 0.8 mM and a maximum productivity of 1.0 ± 0.05 mM/h. These proof-of-principle demonstrations may ultimately find their way to the manufacture of diverse chemicals from ethanol and other simple carbon compounds.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2016

AF-M315E Propulsion System Advances and Improvements

Even as for the GR-1 awaits its first on-orbit demonstration on the planned 2017 launch of NASA's Green Propulsion Infusion Mission (GPIM) program, ongoing efforts continue to advance the technical state-of-the-art through improvements in the performance, life capability, and affordability of both Aerojet Rocketdyne's 1-N-class GR-1 and 20-N-class GR-22 green monopropellant thrusters. Hot-fire testing of a design upgrade of the GR-22 thruster successfully demonstrated resolution of a life-limiting thermo-structural issue encountered during prototype testing on the GPIM program, yielding both an approximately 2x increase in demonstrating life capability, as well as fundamental insights relating to how ionic liquid thrusters operate, thruster scaling, and operational factors affecting catalyst bed life. Further, a number of producibility improvements, related to both materials and processes and promising up to 50% unit cost reduction, have been identified through a comprehensive Design for Manufacturing and Assembly (DFMA) assessment activity recently completed at Aerojet Rocketdyne. Focused specifically on the GR-1 but applicable to the common-core architecture of both thrusters, ongoing laboratory (heavyweight) thruster testing being conducted under a Space Act Agreement at NASA Glenn Research Center has already validated a number of these proposed manufacturability upgrades, additionally achieving a greater than 40% increase in thruster life. In parallel with technical advancements relevant to conventional large spacecraft, a joint effort between NASA and Aerojet Rocketdyne is underway to prepare 1-U CubeSat AF-M315E propulsion module for first flight demonstration in 2018.

Liquid propulsion↗

NASA NTRS2001

Accurate Time-Dependent Traveling-Wave Tube Model Developed for Computational Bit-Error-Rate Testing

The phenomenal growth of the satellite communications industry has created a large demand for traveling-wave tubes (TWT's) operating with unprecedented specifications requiring the design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies on computational modeling. However, the TWT industry's computational modeling capabilities need to be improved because there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This limits the analysis and design of novel devices or TWT's with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. To address these concerns, a fully three-dimensional, time-dependent, helical TWT interaction model was developed using the electromagnetic particle-in-cell code MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm). The model includes a short section of helical slow-wave circuit with excitation fed by radiofrequency input/output couplers, and an electron beam contained by periodic permanent magnet focusing. A cutaway view of several turns of the three-dimensional helical slow-wave circuit with input/output couplers is shown. This has been shown to be more accurate than conventionally used two-dimensional models. The growth of the communications industry has also imposed a demand for increased data rates for the transmission of large volumes of data. To achieve increased data rates, complex modulation and multiple access techniques are employed requiring minimum distortion of the signal as it is passed through the TWT. Thus, intersymbol interference (ISI) becomes a major consideration, as well as suspected causes such as reflections within the TWT. To experimentally investigate effects of the physical TWT on ISI would be prohibitively expensive, as it would require manufacturing numerous amplifiers, in addition to acquiring the required digital hardware. As an alternative, the time-domain TWT interaction model developed here provides the capability to establish a computational test bench where ISI or bit error rate can be simulated as a function of TWT operating parameters and component geometries. Intermodulation products, harmonic generation, and backward waves can also be monitored with the model for similar correlations. The advancements in computational capabilities and corresponding potential improvements in TWT performance may prove to be the enabling technologies for realizing unprecedented data rates for near real time transmission of the increasingly larger volumes of data demanded by planned commercial and Government satellite communications applications. This work is in support of the Cross Enterprise Technology Development Program in Headquarters' Advanced Technology & Mission Studies Division and the Air Force Office of Scientific Research Small Business Technology Transfer programs.

Kory, Carol L.↗

DOE OSTI2021

Flexible 3D printed silicones for gamma and neutron radiation shielding

Here, resin formulations for direct ink write (DIW) additive manufacturing (AM) were developed for facile customization to shield radiation signatures consisting of a range of gamma radiation and neutron energies in a variety of applications. The resin developed in this work has been formulated to accommodate very high loadings of shielding filler materials: up to 40 wt% bismuth (Bi) metal for gamma radiation shielding, and up to 60 wt% boron-10 ( 10 B) metal for neutron shielding. We report the first instance of a printable resin containing 60 wt% 10 B, which remains flexible after curing despite the high solids content. We demonstrate that these resins can not only tolerate formulation modulation for radiation profile-matched shielding, but they can also be printed in a variety of geometries such that mechanical properties of the printed shield are readily tuned to specific applications. In contrast, most existing shielding materials are rigid, bulky, and do not allow for the complex shapes and mechanical flexibility needed in high-usage applications. This work demonstrates the successful development of a tunable resin for additively manufactured, flexible radiation shielding material, containing high loadings of shielding filler, which can be utilized in harsh radiation environments associated with nuclear materials.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2022

Phase Transitions of Cu and Fe at Multiscales in an Additively Manufactured Cu–Fe Alloy under High-Pressure

A state of the art, custom-built direct-metal deposition (DMD)-based additive manufacturing (AM) system at the University of Michigan was used to manufacture 50Cu–50Fe alloy with tailored properties for use in high strain/deformation environments. Subsequently, we performed preliminary high-pressure compression experiments to investigate the structural stability and deformation of this material. Our work shows that the alpha (BCC) phase of Fe is stable up to ~16 GPa before reversibly transforming to HCP, which is at least a few GPa higher than pure bulk Fe material. Furthermore, we observed evidence of a transition of Cu nano-precipitates in Fe from the well-known FCC structure to a metastable BCC phase, which has only been predicted via density functional calculations. Finally, the metastable FCC Fe nano-precipitates within the Cu grains show a modulated nano-twinned structure induced by high-pressure deformation. The results from this work demonstrate the opportunity in AM application for tailored functional materials and extreme stress/deformation applications.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Charging and Heating Dynamics of Nanoparticles in Nonthermal Plasmas

The focus of this award was to understand the interactions of nanometer-sized particles with ionized gases, also called plasmas. Plasmas are widely used in the fabrication of electronic circuits such as microprocessors and memory devices, in plasma display panels, as well as in medical applications. Recently, these ionized gases are finding applications in the synthesis of advanced nanomaterials with novel properties, which are based on nanometer-sized particulate (nanoparticles) building blocks. As these nanoparticles grow in the plasma environment, they interact with the plasmas species such as electrons and ions which critically determines the nanoparticle properties. The University of Minnesota researchers conducting this project performed numerical simulations and developed analytical models that described the interaction of plasma-bound nanoparticles with the plasma ions. The plasma ions bombard the nanoparticle surface with substantial energy, which can result in the rearrangement of the nanoparticles’ atoms, giving them often desirable structures at the atomic scale. Being able to tune the ion energies allows to control the properties of nanoparticles produced in order to tailor their attributes for certain applications. For instance, when used in high efficiency light emitting devices, nanoparticles produced under high fluxes of highly energetic ions may show superior light emission to particles produced under low fluxes of less energetic ions. The analytical models developed by the University of Minnesota researchers enable the research community to easily determine the energy of ions bombarding the nanoparticles. The researchers extensively tested the validity of the analytical models by comparing them to sophisticated computer simulations based on stochastic particle modeling, also called Monte Carlo modeling, which simulated the motion of hundreds of thousands of ions and their interaction with the nanoparticle surfaces. Beyond the scientific intellectual merits, this award had significant broader impacts. Two graduate students received their doctoral degrees and both have joined a U.S. manufacturer of plasma-based semiconductor processing equipment. Four undergraduate students participated in research conducted under this grant and gained valuable hands-on laboratory experience. A middle school science teacher observed research conducted under this grant and developed three new course modules that introduce middle school students to the concepts of nanometer scale, the atomic structure of matter, and the composition of matter of different chemical elements.

42 ENGINEERING↗

DOE OSTI2022

III-V Solar Cells with Novel Epitaxial Lift-off Architectures for Extended Substrate Reuse for Low-cost Manufacturing

The highest solar cell efficiencies have been achieved with III-V photovoltaics (PV). Still, the use of III-V materials in terrestrial applications has been very limited, mainly because of their high cost. The high cost is primarily due to the expensive Ge or GaAs wafers which could amount up to one-half of the total module cost! A prominent approach to reduce the impact of the high cost of substrates used for III-V PV is through re-use of the wafer substrates by Epitaxial Lift-Off (ELO). Typically, using a sacrificial layer such as AlAs, the device part of the cell is lifted off, leaving behind the substrate for re-use for fabrication of the next device. While conversion efficiency as high as 29.1% has been achieved by ELO method, chemical mechanical polishing (CMP) of the substrate is required which significantly adds to the overall solar cell cost. In this project, we have developed a novel ELO architecture for single junction gallium arsenide (GaAs) solar cells that will not require CMP of the substrate for re-use. Multiple reuses of GaAs wafers have been demonstrated with no CMP, without degradation in solar cell efficiency. Also, the solar cells have been successfully lifted off and transferred to inexpensive substrates with less than 2% change in efficiency. By elimination of the CMP process, which is the highest cost component of III-V solar cells made by conventional ELO method (~$10/W), and decreasing the substrate cost by multiple re-uses, the developed technology could be a leap forward in significantly reducing the cost of III-V photovoltaics.

14 SOLAR ENERGY↗

NASA NTRSDate not supplied

In-Space Modular Assembly: An Approach for Reliable, Affordable, Precision Space Apertures

In-space assembly will revolutionize the creation, upgrade, and evolution of future space systems. In-space assembly represents an alternative deployment strategy that is not constrained by the requirement of using a single launch vehicle and enables a greater freedom of design for the initial emplacement of assets and their evolution over time. In-space assembly enables assets, such as observatories and science platforms, to become persistent, evolving over time like their terrestrial counterparts. Also, in-space assembly provides a direct path for utilization of in-space manufactured components designed exclusively for the operational environment. To highlight the advantages of an in-space assembly approach, the modular assembly of a 3 m to 4 m precision optical aperture based on thin meniscus technology coupled with structurally efficient TriTruss modules is presented. The 3 m to 4 m aperture stows compactly within two standard ride share slots (0.61 m by 0.71 m by 0.97 m). Placing instruments and the robotic system used for assembly in an adjacent ride share slot enables a capable observatory to be placed into service via modest ride share opportunities. Further, recent hardware assembly tests of similar modules and progress toward hardware tests to validate the overall architecture via diffraction limited testing will be summarized.

Design↗

NASA NTRSDate not supplied

In-Space Modular Assembly: An Approach for Reliable, Affordable, Precision Space Apertures

Design↗

DOE OSTI2016

Broadly Applicable Dose Model for Radiotherapy Beams from 6-25 MV

The goal of modern external beam radiotherapy is to deliver a highly targeted radiation dose to a specified treatment volume while sparing the healthy surrounding tissue as much as possible. However, some healthy tissue radiation exposure is unavoidable. Healthy tissue in the margin of the treatment field will receive absorbed doses on the order of the prescribed dose, and tissue far out of field will receive stray dose from scattered and leakage radiation. These doses can lead to late effects such as secondary cancers both near the treatment field and far out of field in tissues only receiving stray radiation dose. Many researchers have investigated algorithms to model absorbed dose from external beam photon radiation therapy; however, none of these works have fully addressed the stray dose far from the treatment field. The AAPM Task Group Report No. 36 described three main sources of stray radiation from external beam radiation therapy delivered with electron linear accelerators. Radiation scattered from the treatment head, known as head scatter, is primarily important within about 10 cm from the field edge. Patient scatter is an important source up to around 30 cm from the field edge. Finally, leakage radiation emanates from the treatment enclosure and predominates the stray radiation dose beyond about 30 cm. Monte Carlo simulations have been a useful research tool for modeling stray dose, but these methods have not found use in clinical settings due to their complexity and long computational times. The feasibility of analytical models to predict stray dose from radiation therapy has been supported by several works, but few attempts have been made at developing models accurate for both in-field and out-of-field doses. Jagetic and Newhauser reported on one such model that predicts absorbed dose from therapeutic, scatter, and leakage radiation with promising results. This model was validated at 6 MV for Conformal Radiation Therapy (CRT) beams from an Elekta linac. Intensity Modulated Radiation Therapy (IMRT) was not considered, and the model has not been tested at beam energies greater than 6 MV. Additionally, this model relies on proprietary, machine specific parameters, and so adapting the model for use on treatment units from other manufacturers is not straightforward. In this study we aim to test whether a physics-based analytical modeling approach is broadly applicable and if sufficient accuracy can be achieved without the need for proprietary, machine specific parameters. In order to accomplish this, a new analytical model was developed that does not rely on machine specific parameters, so that it can easily be trained on measurements from whatever treatment machine is available at a given clinic. This model was tested using measured data from a variety of treatment machines and techniques in the 6 MV to 25 MV energy interval. (authors)

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2024

Large area projection micro stereolithography

A large area projection micro stereolithography (LAPuSL) system uses an addressable spatial light modulator (SLM) in coordination with an optical scanning system to make very large stereolithographically produced objects. The SLM is imaged onto a photosensitive material with an optical system that has the ability to scan the image over a large area and speedily manufacture large scale complex three dimensional components with micro scale features.

Moran, Bryan D.↗

NASA NTRS2000

Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗

DOE OSTI2021

Proton switching molecular magnetoelectricity

Abstract The convergence of proton conduction and multiferroics is generating a compelling opportunity to achieve strong magnetoelectric coupling and magneto-ionics, offering a versatile platform to realize molecular magnetoelectrics. Here we describe machine learning coupled with additive manufacturing to accelerate the design strategy for hydrogen-bonded multiferroic macromolecules accompanied by strong proton dependence of magnetic properties. The proton switching magnetoelectricity occurs in three-dimensional molecular heterogeneous solids. It consists of a molecular magnet network as proton reservoir to modulate ferroelectric polarization, while molecular ferroelectrics charging proton transfer to reversibly manipulate magnetism. The magnetoelectric coupling induces a reversible 29% magnetization control at ferroelectric phase transition with a broad thermal hysteresis width of 160 K (192 K to 352 K), while a room-temperature reversible magnetic modulation is realized at a low electric field stimulus of 1 kV cm −1 . The findings of electrostatic proton transfer provide a pathway of proton mediated magnetization control in hierarchical molecular multiferroics.

36 MATERIALS SCIENCE↗