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Mechanism of Pinhole Formation in Membrane Electrode Assemblies for PEM Fuel Cells

The pinhole formation mechanism was studied with a variety of MEAs using ex-situ and in-situ methods. The ex-situ tests included the MEA aging in oxygen and MEA heat of ignition. In-situ durability tests were performed in fuel cells at different operating conditions with hydrogen and oxygen. After the in-situ failure, MEAs were analyzed with an Olympus BX 60 optical microscope and Cambridge 120 scanning electron microscope. MEA chemical analysis was performed with an IXRF EDS microanalysis system. The MEA failure analyses showed that pinholes and tears were the MEA failure modes. The pinholes appeared in MEA areas where the membrane thickness was drastically reduced. Their location coincided with the stress concentration points, indicating that membrane creep was responsible for their formation. Some of the pinholes detected had contaminant particles precipitated within the membrane. This mechanism of pinhole formation was correlated to the polymer blistering.

Stanic, Vesna↗

Generic system components of the Thiokol ultrasonic RSRM case-to-insulation bondline inspection system

Qualification testing of the Ultrasonic Redesigned Solid Rocket Motor Bondline Inspection Systems (URBIS) was conducted at the Thiokol Nondestructive Evaluation Test Facility M337A and at the Rotation Process Storage Facility at Kennedy Space Center. The test was performed on portions of the URBIS that are generic to redesigned solid rocket motor case-to-insulation bondline inspections. Testing began on Feb. 13, 1989 and was completed on May 26, 1989. The main purpose of the test was to verify that each URBIS performed to the manufacturer's specifications in the same manner and to make any procedural changes necessary for specific redesigned solid rocket motor inspections. All five URBISs passed every stage of the qualification test. Each URBIS is now qualified for use on redesigned solid rocket motors. Verifying the fact that each URBIS obtains and analyzes data in a similar fashion has eliminated concerns about variations in data between the five systems. The following recommendations were made as a result of this test: (1) each URBIS should be located within a stable environment; (2) an electronic preventative maintenance program should be established for each URBIS; (3) when the URBIS is being utilized to perform transducer analysis, the URBIS equipment setting should match the equipment setting noted on the manufacturer-supplied transducer certification sheet; and (4) optimum scan velocities for each inspection technique (clevis, capture feature, pinhole and membrane) should be determined through further testing.

Cook, M.↗

Uncooled tunneling infrared sensor

An uncooled infrared tunneling sensor in which the only moving part is a diaphragm which is deflected into contact with a micromachined silicon tip electrode prepared by a novel lithographic process. Similarly prepared deflection electrodes employ electrostatic force to control the deflection of a silicon nitride, flat diaphragm membrane. The diaphragm exhibits a high resonant frequency which reduces the sensor's sensitivity to vibration. A high bandwidth feedback circuit controls the tunneling current by adjusting the deflection voltage to maintain a constant deflection of the membrane. The resulting infrared sensor can be miniaturized to pixel dimensions smaller than 100 .mu.m. An alternative embodiment is implemented using a corrugated membrane to permit large deflection without complicated clamping and high deflection voltages. The alternative embodiment also employs a pinhole aperture in a membrane to accommodate environmental temperature variation and a sealed chamber to eliminate environmental contamination of the tunneling electrodes and undesireable accoustic coupling to the sensor.

Kenny, Thomas W.↗

Progress in Development of Improved Ion-Channel Biosensors

Further improvements have recently been made in the development of the devices described in Improved Ion-Channel Biosensors (NPO-30710), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 30. As discussed in more detail in that article, these sensors offer advantages of greater stability, greater lifetime, and individual electrical addressability, relative to prior ion-channel biosensors. In order to give meaning to a brief description of the recent improvements, it is necessary to recapitulate a substantial portion of the text of the cited previous article. The figure depicts one sensor that incorporates the recent improvements, and can be helpful in understanding the recapitulated text, which follows: These sensors are microfabricated from silicon and other materials compatible with silicon. Typically, the sensors are fabricated in arrays in silicon wafers on glass plates. Each sensor in the array can be individually electrically addressed, without interference with its neighbors. Each sensor includes a well covered by a thin layer of silicon nitride, in which is made a pinhole for the formation of a lipid bilayer membrane. In one stage of fabrication, the lower half of the well is filled with agarose, which is allowed to harden. Then the upper half of the well is filled with a liquid electrolyte (which thereafter remains liquid) and a lipid bilayer is painted over the pinhole. The liquid contains a protein that forms an ion channel on top of the hardened agarose. The combination of enclosure in the well and support by the hardened agarose provides the stability needed to keep the membrane functional for times as long as days or even weeks. An electrode above the well, another electrode below the well, and all the materials between the electrodes together constitute a capacitor. What is measured is the capacitive transient current in response to an applied voltage pulse. One notable feature of this sensor, in comparison with prior such sensors, is a relatively thick dielectric layer between the top of the well and the top electrode. This layer greatly reduces the capacitance of an aperture across which the ion channels are formed, thereby increasing the signal-to-noise ratio. The use of a relatively large aperture with agarose support makes it possible to form many ion channels instead of only one, thereby further increasing the signal-to-noise ratio and effectively increasing the size of the available ionic reservoir. The relatively large reservoir makes it possible to measure AC rather than DC. This concludes the recapitulation from the cited previous article.

Nadeau, Jay L.↗

Fabrication of Monolithic Sapphire Membranes for High Tc Bolometer Array Development

This paper examines the effectiveness of Pt/Cr thin film masks for the architecture of monolithic membrane structures in r-plane sapphire. The development of a pinhole-free Pt/Cr composite mask that is resistant to hot H2SO4:H3PO4 etchant, will lead to the fabrication of smooth sapphire membranes whose surfaces are well-suited for the growth of low-noise high Tc films. In particular, the relationship of thermal annealing conditions on the Pt/Cr composite mask system to: (1) changes in the surface morphology and elemental concentration of the Pt/Cr thin film layers and (2) etch pit formation on the sapphire surface will be presented.

Pugel, D. E.↗

Fabrication of Monolithic Sapphire Membranes for High T(sub c) Bolometer Array Development

This paper examines the effectiveness of Pt/Cr thin film masks for the architecture of monolithic membrane structures in r-plane single crystal sapphire. The development of a pinhole-free Pt/Cr composite mask that is resistant to boiling H2SO4:H3PO4 etchant will lead to the fabrication of smooth sapphire membranes whose surfaces are well-suited for the growth of low-noise high Tc films. In particular, the relationship of thermal annealing conditions on the Pt/Cr composite mask system to: (1) changes in the surface morphology (2) elemental concentration of the Pt/Cr thin film layers and (3) etch pit formation on the sapphire surface will be presented.

Pugel, D. E.↗

Technology and Opportunities of Photon Sieve CubeSat with Deployable Optical Membrane

A photon sieve (PS) is a revolutionary optical instrument that provides high resolution imaging at a fraction of the weight of typical telescopes, with an areal density of 0.3 kg/m2 compared to 25 kg/m2 for the James Webb Space Telescope. The photon sieve is a variation of a Fresnel Zone Plate consisting of many small holes arranged in a series of concentric rings. The sieve works by diffracting light of a certain wavelength to a specified focal point for imaging, so that only a specific wavelength can be imaged. Moreover, the better image contrast and higher signal-to-noise ratios come from suppressing higher diffracted orders by apodizing the number of pinholes in the outer rings. Finally, a photon sieve requires less supports and can withstand more deformation without a reduction in the imaging qualities. Due to these properties, various groups have created PS CubeSats for Earth and Sun imaging at a low cost and weight specifically using deployable technology. A team at the Air Force Research Laboratory created a design and prototype of a mechanism that deploys a 20 cm diameter photon sieve. The United States Air Force Laboratory used a similar design to create a CubeSat-based deployable photon sieve. The team at NASA Langley Research Center has researched photon sieves for conducting an Earth-observing experiment using LIDAR (Light Detection and Ranging) with a higher signal-to-noise ratio benefit from the PS. This paper provides a state of the art overview on existing PS CubeSat technology with deployable structures and applications. Especially, the paper introduces PS for LIDAR applications and discusses the CubeSat-based PS challenge being worked at the NASA Langley Research Center.

Hyun Jung Kim↗