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NASA NTRS1982

Deposit formation in hydrocarbon rocket fuels with an evaluation of a propane heat transfer correlation

A high pressure fuel coking testing apparatus was designed and developed and was used to evaluate thermal decomposition limits and carbon decomposition rates in heated copper tubes for hydrocarbon fuels. A commercial propane (90% grade) and chemically pure (CP) propane were tested. Heat transfer to supercritical propane was evaluated at 136 atm, bulk fluid velocities of 6 to 30 m/s, and tube wall temperatures in the range of 422 to 811 K. A forced convection heat transfer correlation developed in a previous test effort verified a prediction of most of the experimental data within a + or - 30% range, with good agreement for the CP propane data. No significant differences were apparent in the predictions derived from the correlation when the carbon resistance was included with the film resistance. A post-test scanning electron microprobe analysis indicated occurrences of migration and interdiffusion of copper into the carbon deposit.

Masters, P. A.↗

NASA NTRS1982

Efficiency of silicon solar cells containing chromium

Efficiency of silicon solar cells containing about one quadrillon atoms cu cm of chromium is improved about 26% by thermal annealing of the silicon wafer at a temperature of 200 C to form chromium precipitates having a diameter of less than 1 Angstrom. Further improvement in efficiency is achieved by scribing laser lines onto the back surface of the wafer at a spacing of at least 0.5 mm and at a depth of less than 13 micrometers to preferentially precipitate chromium near the back surface and away from the junction region of the device. This provides an economical way to improve the deleterious effects of chromium, one of the impurities present in metallurgical grade silicon mateial.

Salama, A. M.↗

NASA NTRS1982

Silicon production process evaluations

Engineering design of the third distillation column in the process was accomplished. The initial design is based on a 94.35% recovery of dichlorosilane in the distillate and a 99.9% recovery of trichlorosilane in the bottoms. The specified separation is achieved at a reflux ratio of 15 with 20 trays (equilibrium stages). Additional specifications and results are reported including equipment size, temperatures and pressure. Specific raw material requirements necessary to produce the silicon in the process are presented. The primary raw materials include metallurgical grade silicon, silicon tetrachloride, hydrogen, copper (catalyst) and lime (waste treatment). Hydrogen chloride is produced as by product in the silicon deposition. Cost analysis of the process was initiated during this reporting period.

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NASA NTRS1982

Investigation of the hydrochlorination of SiCl4

A research and development program on the hydrochlorination of silicon tetrachloride and metallurgical grade (m.g.) silicon metal to trichlorosilane was carried out as scheduled. Effects of pressure and temperature on this reaction are reported. The presence of HCl in the reaction product mixture was successfully analyzed. Approximately 0.1% to 0.5% HCl based on total chlorosilanes were produced by the hydrochlorination reaction. Experiments on the corrosion study were carried out to evaluate a variety of metals and alloys as the material of construction for the hydrochlorination reactor. Material includes carbon steel, nickel, copper, Alloy 400 (Monel), stainless steel (Type 304), Incoloy 800H and Hastelloy B-2. The corrosion test was carried out at reaction temperature of 500 C, pressure of 300 psig and H2/SiCl4 feed ratio of 2.0 for a total of 87 hours. Results of the corrosion test show that all the test samples achieved a weigh gain.

Mui, J. Y. P.↗

NASA NTRS1981

Evaluation and verification of epitaxial process sequence for silicon solar-cell production

To achieve the program goals, 28 minimodules were fabricated and tested, using 600 cells made from three-inch-diameter wafers processed by the sequence chosen for this purpose. Of these 600 cells, half were made from epitaxially grown layers on potentially low-cost substrates. The other half were made from commercial semiconductor-grade (SG), single-crystal silicon wafers that served as controls. Cell processing was normally performed on mixed lots containing significant numbers of each of these two types of wafers. After evaluation of the performance of all cells, they were separated by types for incorporation into modules that were to be tested for electrical performance and response to environmental stress. A simplified flow chart displaying this scheme, for quantities representing half of the planned total to be processed, is presented.

Redfield, D.↗

NASA NTRS1982

Silicon materials task of the Low Cost Solar Array Project: Effect of impurities and processing on silicon solar cells

The effects of impurities and processing on the characteristics of silicon and terrestrial silicon solar cells were defined in order to develop cost benefit relationships for the use of cheaper, less pure solar grades of silicon. The amount of concentrations of commonly encountered impurities that can be tolerated in typical p or n base solar cells was established, then a preliminary analytical model from which the cell performance could be projected depending on the kinds and amounts of contaminants in the silicon base material was developed. The impurity data base was expanded to include construction materials, and the impurity performace model was refined to account for additional effects such as base resistivity, grain boundary interactions, thermal processing, synergic behavior, and nonuniform impurity distributions. A preliminary assessment of long term (aging) behavior of impurities was also undertaken.

Hopkins, R. H.↗

NASA NTRS1981

Operations analysis of gravity assisted rapid transit

Gravity assisted rapid transit (GART) with 6 percent grades before and after each station are compared with conventional systems in terms of energy consumption, run time, line capacity and schedule stability under abnormal circumstances. Parametric analyses of run times and energy consumption include the impact of alternate accelerating and braking levels. The capcity analysis uses a network simulation program to determine the location and severity of all signal delays. Based on results of initial simulations, the block design was revised to eliminate bottlenecks in normal operations. The systems are then compared at headways of 80 to 180 seconds. One month of incidence reports of a modern operating transit system are reviewed to determine the failures to be simulated. The impact of failures resulting in station delays (30 to 360 seconds), speed limit reduction (20 mph and 30 mph to one or more trains), vehicle performance (75 percent acceleration) are compared at scheduled headway of 90 to 180 seconds.

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NASA NTRS1982

Advanced ceramic coating development for industrial/utility gas turbines

A program was conducted with the objective of developing advanced thermal barrier coating (TBC) systems. Coating application was by plasma spray. Duplex, triplex and graded coatings were tested. Coating systems incorporated both NiCrAly and CoCrAly bond coats. Four ceramic overlays were tested: ZrO2.82O3; CaO.TiO2; 2CaO.SiO2; and MgO.Al2O3. The best overall results were obtained with a CaO.TiO2 coating applied to a NiCrAly bond coat. This coating was less sensitive than the ZrO2.8Y2O3 coating to process variables and part geometry. Testing with fuels contaminated with compounds containing sulfur, phosphorus and alkali metals showed the zirconia coatings were destabilized. The calcium titanate coatings were not affected by these contaminants. However, when fuels were used containing 50 ppm of vanadium and 150 ppm of magnesium, heavy deposits were formed on the test specimens and combustor components that required frequent cleaning of the test rig. During the program Mars engine first-stage turbine blades were coated and installed for an engine cyclic endurance run with the zirconia, calcium titanate, and calcium silicate coatings. Heavy spalling developed with the calcium silicate system. The zirconia and calcium titanate systems survived the full test duration. It was concluded that these two TBC's showed potential for application in gas turbines.

Vogan, J. W.↗

NASA NTRS1981

Wideband comet camera lens design

A quarter-meter diameter, modified Ritchey-Chretien camera is described for spacecraft-based observation of Halley's Comet. The system will operate over an unusually broad spectral region, from 0.1216 micron (the hydrogen Lyman-alpha line) to 1.1 microns using reflective primary and secondary mirror optics and a thin UV-grade lithium fluoride refractive element as a field corrector near the image plane. The f/12, 3000 mm focal length camera has a 0.4 deg full field of view for operation with a 15 x 15 mm charge-coupled device detector array. The UV-enhanced silicon CCD detector is a 1000 x 1000 array of 15 micron pixels which establishes the system resolution requirement. The optical design and performance are discussed, with an emphasis on the image analysis with respect to pixel resolution elements used for viewing extended objects such as comets.

Huber, E. D.↗

NASA NTRS1981

Cristobalite-pyroxene in an L6 chondrite - Implications for metamorphism

CRISPY is a cristobalite-pyroxene assemblage in the L6 chondrite ALHA 76003. It was formed by reaction of a very siliceous inclusion with the surrounding olivine-rich rock. Oxygen isotopes show that the inclusion was derived from a source with non-chondritic isotopic composition. The isotopes also show that the oxygen of the pyroxene reaction product was derived by simple mixing of oxygen from the inclusion and its immediately adjacent surroundings, with exchange with the bulk meteorite limited to a distance of about a millimeter. The persistence of cristobalite in close proximity to olivine, and the lack of isotopic equilibration, show that the metamorphic processes that form petrographic grade 6 chondrites involve transport of major elements over distances only on the order of millimeters.

Olsen, E. J.↗

NASA NTRS1981

New technologies for solar energy silicon - Cost analysis of dichlorosilane process

A reduction in the cost of silicon for solar cells is an important objective in a project concerned with the reduction of the cost of electricity produced with solar cells. The cost goal for the silicon material is about $14 per kg (1980 dollars). The process which is currently employed to produce semiconductor grade silicon from trichlorosilane is not suited for meeting this cost goal. Other processes for producing silicon are, therefore, being investigated. A description is presented of results obtained for the DCS process which involves the production of dichlorosilane as a silicon source material for solar energy silicon. Major benefits of dichlorosilane as a silicon source material include faster reaction rates for chemical vapor deposition of silicon. The DCS process involves the reaction 2SiHCl3 yields reversibly SiH2Cl2 + SiCl4. The results of a cost analysis indicate a total product cost without profit of $1.29/kg of SiH2Cl2.

Yaws, C. L.↗

NASA NTRS1981

Relatively low-temperature pyrolysis of silane in free space

The continuous flow pyrolyzer is a free space reactor that is used to study the effects of concentration, flow rate and temperature in making solar-grade silicon by pyrolysis of silane gas. Work with the continuous flow pyrolyzer is within the DOE-sponsored Low-Cost Solar Array Project. The work has led to a new theoretical treatment of silane pyrolysis in free space at relatively low temperatures (550 C to 750 C). It involves a sequential, three-step mechanism of particle growth: first, silicon atom generation by homogeneous reaction; second, coagulation to a 0.1 micron particle due to Brownian motion and van der Waals forces; and finally, chemical vapor deposition by heterogeneous reaction to final particle size.

Levin, H.↗

NASA NTRS1982

Deposit formation in hydrocarbon fuels

The hydrocarbon fuels RP-1, commercial-grade propane, JP-7 and chemically pure propane were subjected to tests in a high pressure fuel coking apparatus in order to evaluate their thermal decomposition limits and carbon deposition rates in heated copper tubes. A fuel thermal stability parametric evaluation was conducted at 136-340 atmospheres, bulk fuel velocities of 6-30 m/sec, and tube wall temperatures of 422-811 K, and the effect of inside wall material on deposit formation was evaluated in tests using nickel-plated tubes. Results show RP-1 deposit formation at wall temperatures between 600 and 800 K, with peak deposit formation near 700 K. Substitution of deoxygenated JP-7 for RP-1 showed no improvement, and the carbon deposition rates for propane fuels were found to be higher than those of either of the kerosene fuels. Nickel plating of the tube walls significantly reduced RP-1 carbon deposition rates.

Roback, R.↗

NASA NTRS1981

Solar cells fabricated with unconventional silicon materials

Solar cells have been fabricated using silicon materials supplied in the DOE/JPL Large Solar Array program. Each of the silicon materials studied in this program was produced in a unique manner and with intent of producing silicon in a grade and form that would offer the possibility of economic deployment in photovoltaic arrays for generation of electricity. This report will attempt to provide an overview of the results for some of the materials and highlight in particular results obtained for solar cells fabricated from the advanced CZ silicon. Emphasis will be given to consideration of the purity of virgin silicon material used in the heat exchange method.

Minahan, J. A.↗

NASA NTRS1981

A study of decision-making behavior of aircraft pilots deviating from a planned flight

This paper outlines an investigation into the worth structures of pilots facing a deviation from a planned flight. A 'paper and pencil' simulation was used to frame the situation into which pilots interjected their own decision making skills in a simple ranking of candidate diversion airports with varying locational, navigational aid, radar and weather attributes. Using the conjoint measurement technique, attribute worth functions of 30 pilots were constructed. It was discovered that systematic differences in the worth functions of the pilots did not occur as a result of dividing the pilot sample according to any measure of flight hour experience. However, differences were found when the pilot sample was grouped according to grade of pilot certificate, type of pilot training, and type of flying most commonly done.

Flather, G. W., II↗

NASA NTRS1982

The Shuttle Student Involvement Project for Secondary Schools - Reports on first flights

During the 1980-81 academic year, NASA established the Shuttle Student Involvement Project for Secondary Schools (SSIP), an annual competition which invites students to propose experiments suitable for flight aboard the Space Shuttle. The purpose of the project is to stimulate the teaching and study of science and engineering among students in grades 9 through 12. Results of the first year of the project have been reported. The second competition was announced in September 1981. With a February 1, 1982 deadline, 2,800 proposals were submitted. Twenty national winners were announced in May 1982. NASA is now pairing the 20 winners with a corporate sponsor and with a NASA scientist or engineer to work with the student. Most SSIP experiments are performed in the Orbiter's mid-deck, and receive up to one hour of crew time. Attention is given to the desired outcomes of SSIP, and the SSIP experiments.

Ladwig, A.↗

NASA NTRS1984

Silicon Nitride Antireflection Coatings for Photovoltaic Cells

Chemical-vapor deposition adapted to yield graded index of refraction. Silicon nitride deposited in layers, refractive index of which decreases with distance away from cell/coating interface. Changing index of refraction allows adjustment of spectral transmittance for wavelengths which cell is most effective at converting light to electric current. Average conversion efficiency of solar cells increased from 8.84 percent to 12.63 percent.

Johnson, C.↗

NASA NTRS1982

Aviation turbine fuels: An assessment of alternatives

The general outlook for aviation turbine fuels, the effect that broadening permissible aviation turbine fuel properties could have on the overall availability of such fuels, the fuel properties most likely to be affected by use of lower grade petroleum crudes, and the research and technology required to ensure that aviation turbine fuels and engines can function satisfactorily with fuels having a range of fuel properties differing from those of current specification fuel are assessed. Views of industry representatives on alternative aviation turbine fuels are presented.

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