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At least 127 records · Page 7

Advancements in Manufacturing of High-Performance Perovskite Solar Cells and Modules Using Printing Technologies

Perovskite photovoltaic technology carries immense opportunity for the solar industries because of its remarkable efficiency and prospect for cost-effective production. However, the successful deployment of perovskite solar modules (PSMs) in the solar market necessitates tackling stability-based obstacles, scalability, and environmental considerations. This paper unveils a comprehensive examination of the cutting-edge advancements in the manufacturing of perovskite solar cells (PSCs) and modules, with an emphasis on high-speed, large-area printing. The paper underscores the substantial progress achieved in printed PSCs and PSMs, demonstrating promising electrical performance and long-term device durability. This review paper categorizes printing techniques compatible with large-area high-speed manufacturing into three distinct families: blade coating, slot die coating, and screen printing, as these common printing practices offer precise control, scalability, cost-effectiveness, high resolution, and efficient material usage. Additionally, this paper presents an in-depth investigation and comparison of superior PSCs and PSMs fabricated by printing on power conversion efficiency (PCE), stability, and scalability.

14 SOLAR ENERGY↗

High-Temperature Hybrid Rotor Support System Developed

The Army Research Laboratory Vehicle Technology Directorate and the NASA Glenn Research Center demonstrated a unique high-speed, high-temperature rotor support system in September 2003. Advanced turbomachinery is on its way to surpassing the capabilities of rolling-element bearings and conventional dampers. To meet these demands, gas turbine engines of the future will demand increased efficiency and thrust-to-weight ratio, and reduced specific fuel consumption and noise. The more-electric engine replaces oil-lubricated bearings, dampers, gears, and seals with electrical devices. One such device is the magnetic bearing. The Vehicle Technology Directorate and Glenn have demonstrated the operation of a radial magnetic bearing in combination with a hydrostatic bearing at 1000 F at 31,000 rpm (2.3 MDN1). This unique combination takes advantage of a high-temperature rub surface in the event of electrical power loss or sudden overloads. The hydrostatic bearings allow load sharing with the magnetic bearing. The magnetic-hydrostatic bearing combination eliminates wear and high contact stress from sudden acceleration of the rolling-element bearings and overheating. The magnetic bearing enables high damping, adaptive vibration control, and precise rotor positioning, diagnostics, and health monitoring. A model of the test facility used at Glenn for this technology demonstration is shown. A high-temperature heteropolar radial magnetic bearing is located at the center of gravity of the test rotor. There is a 0.022-in. radial air gap between the rotor and stator. Two rub surface hydrostatic bearings were placed on either side of the magnetic bearing. The rotor is supported by a 0.002-in. hydrostatic air film and the magnetic field. The prototype active magnetic bearing cost $24,000 to design and fabricate and a set of four high temperature, rub-surface, hydrostatic bearings cost $28,000. This work was funded by the Turbine-Based Combined Cycle program.

Montague, Gerald T.↗

Repurposing the James Webb Space Telescope’s center of curvature optical bench hexapod for future mirror calibration testing at NASA Marshall’s x-ray & cryogenic facility

The James Webb Space Telescope’s (JWST) center of curvature optical bench (CoCOB) hexapod was repurposed to enhance NASA Marshall Space Flight Center’s X-Ray & Cryogenic Facility (XRCF) optical metrology capabilities. This upgrade unlocked higher test article load capacity and extended the allowable ranges of motion of the CoCOB hexapod. The hexapod was also coupled to a new long-stroke, linear motion axis to form a 7 degrees of freedom system and allow for high precision testing of larger diameter test articles. A 9 degrees of freedom motion system, consisting of a three-axis linear mount in an X-Y-Z configuration and a commercially available hexapod, was also designed to allow high resolution positioning of the focal plane instrumentation over a large range of motion. A modern control architecture and graphical user interface was developed for the CoCOB hexapod and additional motion stages to permit streamlined commanding and operation. This paper discusses the justification for re-using the CoCOB hexapod by highlighting its unique precision motion control capabilities in a high vacuum and optically clean environment. The design, key component selection, and environmental compatibility for each of the additional motion stages is presented along with testing results for achieved range, repeatability, and minimum step size performance for all motion axes. Finally, a summary of the motion control system architecture and its flexibility to address tomorrow’s optical metrology needs are presented.

hexapod↗

Additive manufacturing of soft magnetic high entropy alloys: A review

Additive manufacturing (AM) offers unique advantages in fabricating soft magnetic high-entropy alloys (HEAs), enabling precise control over material properties and the development of advanced components for applications such as magnetic cores, electric motors, and transformers. These HEAs exhibit superior magnetic performance, mechanical strength, and thermal stability, making them highly suitable for modern electronics applications. Here, this review explores the advancements in AM-processed soft magnetic HEAs, including ongoing research on process optimization, tailored microstructures, and enhanced magnetic properties. It emphasizes the importance of understanding the correlations between AM process parameters, resulting microstructures, and the soft magnetic properties of HEAs. By summarizing the state of the field, we provide insights into current progress and highlight future research trends, focusing on the potential for industrial adoption and advancements in this emerging area.

36 MATERIALS SCIENCE↗

Thruster Limitation Consideration for Formation Flight Control

Physical constraints of any real system can have a drastic effect on its performance. Some of the more recognized constraints are actuator and sensor saturation and bandwidth, power consumption, sampling rate (sensor and control-loop) and computation limits. These constraints can degrade system s performance, such as settling time, overshoot, rising time, and stability margins. In order to address these issues, researchers have investigated the use of robust and nonlinear controllers that can incorporate uncertainty and constraints into a controller design. For instance, uncertainties can be addressed in the synthesis model used in such algorithms as H(sub infinity), or mu. There is a significant amount of literature addressing this type of problem. However, there is one constraint that has not often been considered; that is, actuator authority resolution. In this work, thruster resolution and controller schemes to compensate for this effect are investigated for position and attitude control of a Low Earth Orbit formation flight system. In many academic problems, actuators are assumed to have infinite resolution. In real system applications, such as formation flight systems, the system actuators will not have infinite resolution. High-precision formation flying requires the relative position and the relative attitude to be controlled on the order of millimeters and arc-seconds, respectively. Therefore, the minimum force resolution is a significant concern in this application. Without the sufficient actuator resolution, the system may be unable to attain the required pointing and position precision control. Furthermore, fuel may be wasted due to high-frequency chattering phenomena when attempting to provide a fine control with inadequate actuators. To address this issue, a Sliding Mode Controller is developed along with the boundary Layer Control to provide the best control resolution constraints. A Genetic algorithm is used to optimize the controller parameters according to the states error and fuel consumption criterion. The tradeoffs and effects of the minimum force limitation on performance are studied and compared to the case without the limitation. Furthermore, two methods are proposed to reduce chattering and improve precision.

Yunjun Xu↗

Formation Control for the Maxim Mission.

Over the next twenty years, a wave of change is occurring in the spacebased scientific remote sensing community. While the fundamental limits in the spatial and angular resolution achievable in spacecraft have been reached, based on today's technology, an expansive new technology base has appeared over the past decade in the area of Distributed Space Systems (DSS). A key subset of the DSS technology area is that which covers precision formation flying of space vehicles. Through precision formation flying, the baselines, previously defined by the largest monolithic structure which could fit in the largest launch vehicle fairing, are now virtually unlimited. Several missions including the Micro-Arcsecond X-ray Imaging Mission (MAXIM), and the Stellar Imager will drive the formation flying challenges to achieve unprecedented baselines for high resolution, extended-scene, interferometry in the ultraviolet and X-ray regimes. This paper focuses on establishing the feasibility for the formation control of the MAXIM mission. The Stellar Imager mission requirements are on the same order of those for MAXIM. This paper specifically addresses: (1) high-level science requirements for these missions and how they evolve into engineering requirements; (2) the formation control architecture devised for such missions; (3) the design of the formation control laws to maintain very high precision relative positions; and (4) the levels of fuel usage required in the duration of these missions. Specific preliminary results are presented for two spacecraft within the MAXIM mission.

Luquette, Richard J.↗

Suppressing CO formation in low-temperature methanol steam reforming via Ce-modified CuZnGa layered oxide catalysts

Cu-based layered double hydroxides (LDHs) are widely recognized as effective catalysts for low-temperature methanol steam reforming, yet achieving high hydrogen productivity together with near-complete suppression of CO formation remains challenging. Here, we report the synthesis and evaluation of a series of CuZnGa LDH-derived catalysts and Ce-modified analogues prepared via an aqueous miscible organic method, which enables high metal dispersion and precise structural control. The optimized CuZnGa catalyst exhibits a hydrogen production rate of 16.9 µmol H 2 ·g cat −1 ·s −1 at 180 °C with an H 2 /CO ratio exceeding 3500, outperforming many state-of-the-art low-temperature systems. Importantly, the incorporation of small amounts of Ce further suppresses CO formation while maintaining high hydrogen productivity. Combined spectroscopic characterization and density functional theory calculations reveal that Ce is incorporated into the LDH lattice by substituting Ga 3+ sites up to a critical threshold, beyond which highly dispersed CeO x species are formed. These species provide mobile lattice oxygen that participates in a Mars-van Krevelen-type pathway, selectively oxidizing CO and suppressing the reverse water-gas shift reaction. This study establishes a clear relationship between Ce speciation, oxygen mobility, and catalytic selectivity in LDH-derived systems. The resulting catalysts demonstrate the potential of interface-engineered Cu-based materials for efficient low-temperature hydrogen production with minimal CO contamination.

09 BIOMASS FUELS↗

New Capability at ORNL: High Precision Uranium Titration

Destructive analytical measurements establish a nuclear facility’s nuclear material inventory and inventory differences for Nuclear Material Accountancy and Control. A nuclear laboratory’s ability to perform accurate high-precision analytical measurements is key for tracking large inventories within a facility’s material balance areas and during production to track material movement through dynamic processes. For uranium, these measurements are made by using several established high-precision measurement protocols. These include isotope dilution mass spectrometry, gravimetry, and potentiometric titrations. Whatever measurement technique a nuclear lab chooses to use, reference materials (RMs) with certified attributes and accompanying uncertainties are used to calibrate measurement systems, and are the cornerstone for accurate results. In addition to calibration, RMs provide for metrological traceability, are used for method development and validation, and thus provide critical evaluations of the appropriateness and performance of analytical processes used. Evaluations may include validation that a method is fit-for-purpose, quantification of systematic and random biases, and the evaluation of long-term and short-term performance metrics. High-precision measurement techniques require that measured attributes be certified to a high degree of precision in the RMs used—ultimately, to a higher degree than that of the measurement technique itself. The US authority on the production of special nuclear material Certified Reference Materials is the NBL Program Office (NBLPO), formally known as New Brunswick Laboratory (NBL). The NBLPO is responsible for the sales and distribution of existing NBL certified reference materials (CRMs) and for the production of the next generation of nuclear RMs. To accomplish its mission, NBLPO is establishing key base capabilities within the DOE laboratory complex that formerly existed at the NBL laboratory. The Nuclear Analytical Chemistry (NAC) section within the Chemical Sciences Division (CSD) at Oak Ridge National Laboratory (ORNL) is currently working with NBLPO to set up laboratory and measurement capabilities to provide measurements and capabilities for production and/or recertification of existing and future CRMs for uranium assay. The NBL-developed high-precision titration (HPT) method is a critically-evaluated, extremely precise and accurate primary method utilized for the determination of uranium content in a variety of uranium materials. The HPT method, combined with detailed balance weighing protocols, provides for an analytical methodology that is unsurpassed in precision and one in which all sources of error have been evaluated, a requirement of CRM certification. HPT capability within the United States was lost with the closure of the labs at NBL. The NAC has been collaborating with NBLPO to stand up and demonstrate the capability to perform uranium assay via HPT at ORNL. HPT can produce results with an expanded uncertainty of approximately 0.01% for pure uranium compounds, with typical precisions of <0.006%. The major tasks required to stand up the method at ORNL were the refurbishment of a dedicated lab and equipment setup, procedure development, analyst training, establishing method-specific quality assurance, and qualification of an analyst to perform the method. This report summarizes these tasks, outlines the documents drafted, and gives the outcome of the qualification titrations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Fracture-tough, corrosion-resistant bearing steels

The fundamental principles allowing design of stainless bearing steels with enhanced toughness and stress corrosion resistance has involved both investigation of basic phenomena in model alloys and evaluation of a prototype bearing steel based on a conceptual design exercise. Progress in model studies has included a scanning Auger microprobe (SAM) study of the kinetics of interfacial segregation of embrittling impurities which compete with the kinetics of alloy carbide precipitation in secondary hardening steels. These results can define minimum allowable carbide precipitation rates and/or maximum allowable free impurity contents in these ultrahigh strength steels. Characterization of the prototype bearing steel designed to combine precipitated austenite transformation toughening with secondary hardening shows good agreement between predicted and observed solution treatment response including the nature of the high temperature carbides. An approximate equilibrium constraint applied in the preliminary design calculations to maintain a high martensitic temperature proved inadequate, and the solution treated alloy remained fully austenitic down to liquid nitrogen temperature rather than transforming above 200 C. The alloy can be martensitically transformed by cryogenic deformation, and material so processed will be studied further to test predicted carbide and austenite precipitation behavior. A mechanistically-based martensitic kinetic model was developed and parameters are being evaluated from available kinetic data to allow precise control of martensitic temperatures of high alloy steels in future designs. Preliminary calculations incorporating the prototype stability results suggest that the transformation-toughened secondary-hardening martensitic-stainless design concept is still viable, but may require lowering Cr content to 9 wt. pct. and adding 0.5 to 1.0 wt. pct. Al. An alternative design approach based on strain-induced martensitic transformation during cryogenic forming, thus removing the high martensitic constraint, may permit alloy compositions offering higher fracture roughness.

Olson, Gregory B.↗

Baseline experiments in teleoperator control

Studies have been conducted at the NASA Langley Research Center (LaRC) to establish baseline human teleoperator interface data and to assess the influence of some of the interface parameters on human performance in teleoperation. As baseline data, the results will be used to assess future interface improvements resulting from this research in basic teleoperator human factors. In addition, the data have been used to validate LaRC's basic teleoperator hardware setup and to compare initial teleoperator study results. Four subjects controlled a modified industrial manipulator to perform a simple task involving both high and low precision. Two different schemes for controlling the manipulator were studied along with both direct and indirect viewing of the task. Performance of the task was measured as the length of time required to complete the task along with the number of errors made in the process. Analyses of variance were computed to determine the significance of the influences of each of the independent variables. Comparisons were also made between the LaRC data and data taken earlier by Grumman Aerospace Corp. at their facilities.

Hankins, W. W., III↗

Design and Performance of the Hitomi/XRISM Adiabatic Demagnetization Refrigerator Controller

The Resolve instrument in the recently launched X-ray Imaging and Spectroscopy Mission (XRISM) is a rebuild of the Soft X-ray Spectrometer (SXS) in Hitomi (aka Astro-H which had an unfortunately brief mission life in 2016). It is a high-resolution non-dispersive soft x-ray spectrometer from nominally 0.3 keV to 12 keV based on a calorimeter detector array operating at 50 mK with a resolution better than 7 eV FWHM at 6 keV. For such sensitive cryogenic instruments, temperature stability has a strong impact on the detector’s performance. The Adiabatic Demagnetization Refrigerator Controller (ADRC) in the XRISM Resolve instrument is an electronics box responsible for high-precision sub-K temperature readout and control of the multi-stage adiabatic demagnetization refrigerator subsystem to achieve a thermal stability better than 2.5 uK RMS (over a 10-minute interval) for the calorimeter detectors in both cryogen (liquid helium) and cryo-free modes. It has direct telemetry/command and power interfaces with the spacecraft. It also provides sensor read-out and heater circuits for decontamination of the filters in the cold aperture. As a part of the discussion on the design and performance of the ADRC, this paper will also include an overall view of the 50 mK temperature control, plus monitor and control of the aperture filter temperature for de-contamination purpose.

ADRC↗

Design and Performance of the Hitomi/XRISM Adiabatic Demagnetization Refrigerator Controller

The Resolve instrument in the recently launched X-ray Imaging and Spectroscopy Mission (XRISM) is a rebuild of the Soft X-ray Spectrometer (SXS) in Hitomi (aka Astro-H which had an unfortunately brief mission life in 2016). It is a high-resolution non-dispersive soft x-ray spectrometer from nominally 0.3 keV to 12 keV based on a calorimeter detector array operating at 50 mK with a resolution better than 7 eV FWHM at 6 keV. For such sensitive cryogenic instruments, temperature stability has a strong impact on the detector’s performance. The Adiabatic Demagnetization Refrigerator Controller (ADRC) in the XRISM Resolve instrument is an electronics box responsible for high-precision sub-K temperature readout and control of the multi-stage adiabatic demagnetization refrigerator subsystem to achieve a thermal stability better than 2.5 uK RMS (over a 10-minute interval) for the calorimeter detectors in both cryogen (liquid helium) and cryo-free modes. It has direct telemetry/command and power interfaces with the spacecraft. It also provides sensor read-out and heater circuits for decontamination of the filters in the cold aperture. As a part of the discussion on the design and performance of the ADRC, this paper will also include an overall view of the 50 mK temperature control, plus monitor and control of the aperture filter temperature for de-contamination purpose.

ADRC↗

Experimental validation of flexible robot arm modeling and control

Flexibility is important for high speed, high precision operation of lightweight manipulators. Accurate dynamic modeling of flexible robot arms is needed. Previous work has mostly been based on linear elasticity with prescribed rigid body motions (i.e., no effect of flexible motion on rigid body motion). Little or no experimental validation of dynamic models for flexible arms is available. Experimental results are also limited for flexible arm control. Researchers include the effects of prismatic as well as revolute joints. They investigate the effect of full coupling between the rigid and flexible motions, and of axial shortening, and consider the control of flexible arms using only additional sensors.

Ulsoy, A. Galip↗

Active-member control of precision structures

This paper presents the results of closed loop experiments that use piezoelectric active-members to control the flexible motion of a precision truss structure. These experiments are directed toward the development of high performance structural systems as part of the Control/Structure Interaction program at JPL. Order of magnitude reductions in dynamic response are achieved with relatively simple control techniques. The practical implementation of high stiffness, high bandwidth active-members in a precision structure highlights specific issues of importance relating to the modelling and implementation of active-member control.

Fanson, J. L.↗

Pulsed radio frequency power modulation for profile control in cryogenic reactive ion etching of silicon gratings

Cryogenic silicon etching with SF 6 /O 2 plasmas enables vertical sidewalls and smooth surfaces for high–aspect-ratio structures, yet precise control of etched profiles (sidewall angle, lateral etching, and linewidth retention) remains challenging under continuous-wave excitation due to coupling among radical fluxes, ion energy distributions, and in situ passivation dynamics. In this work, we investigated pulsed radio frequency bias delivery as a process knob for profile control during cryogenic silicon etching. Systematic experiments on 500 nm-wide, 1 μm-pitch gratings etched to 0.8–1.1 μm depth at 0.5–2 kHz pulsing frequency and 25%–75% duty cycle revealed strong dependencies of etch rate, linewidth, and sidewall angle on modulation conditions. We proposed a conceptual kinetic picture combined with feature-scale electrostatic analysis to understand the alternation of ion-driven etching and passivation recovery between on/off segments and local electric field shaping and modulation of ion trajectories within the trench. Moderate duty cycles (50%–75%) near 1 kHz achieved a balance between anisotropy and etch rate. These results demonstrate pulsed-bias modulation can be utilized to tune directionality and sidewall preservation in cryogenic SF 6 /O 2 etching, which are relevant to photonic, metrology, and quantum device fabrication.

36 MATERIALS SCIENCE↗

Solvation-protection-enabled high-voltage electrolyte for lithium metal batteries

To facilitate the practical application of lithium metal batteries (LMBs), stable interfaces between the electrolyte and the lithium metal must be achieved. Herein, we introduce a solvation protection strategy for designing a functional electrolyte for high-voltage LMBs. Fluoroethylene carbonate (FEC) was introduced as a solvation protection solvent for the difluoroethylene carbonate (DFEC)/trifluoroethyl methyl carbonate (FEMC) electrolyte system to enable the cycling of lithium metal anode. The addition of FEC alters the structures of lithium complexes in solution because of its relatively high solvating power. Through the precise control of the solvation number (> 1) of fluorinated cyclic carbonate (i.e., FEC:DFEC > critical ratio), lithium complexes with Li + solvated solely by FEMC, which decompose on the lithium surface to form detrimental by-products, can be effectively eliminated. Here, the new ternary FEC/DFEC/FEMC system not only maintains the beneficial effect of DFEC in forming a robust solid-electrolyte interphase on the lithium anode, but also confers outstanding anodic stability provided by FEMC, while eliminating detrimental FEMC decomposition through the solvation protection effect of FEC. Clearly, this ternary system outperforms the FEC/FEMC and DFEC/FEMC binary systems in facilitating the stable cycling of LMBs.

25 ENERGY STORAGE↗

Gate assisted turn-off thyristor with cathode shunts and dynamic gate

A 1,000-V, 200-A gate-assisted turn-off thyristor (GATT) is described, whose design features include an interdigitated shunted cathode, a dynamic gate, a means for optimizing the carrier lifetime level, and a bypass diode. The device physics of gate-assisted turn-off are reviewed. Based on this, improvements in the design are described. It is shown that a prime failure mode can be eliminated and that the gate-assist signal voltage can be substantially decreased by employing a shunted cathode emitter. The test data show excellent turn-on characteristics due to the dynamic gate and the long perimeter of the edge of the main cathode. Turn-off times as short as 3 microsec are obtained. The combination of controlling the carrier lifetime with a precisely controlled and easily variable irradiation dose of high energy electrons with gate assist current provides for simple, precision tailoring of the device characteristics to the intended application.

Schlegel, E. S.↗