Materials & Coatings

Improved Single-Source Precursors for Solar-Cell Absorbers

Deposition properties and final compositions can be tailored. Improved single-source precursor compounds have been invented for use in spray chemical vapor deposition (spray CVD) of chalcopyrite semiconductor absorber layers of thin-film solar photovoltaic cells. The semiconductors in question are denoted by the general formula CuInxGa1–xSySe2–y, where x≤1 and y≤2. These semiconductors have been investigated intensively for use in solar cells because they exhibit longterm stability and a high degree of tolerance of radiation, and their bandgaps correlate well with the maximum photon power density in the solar spectrum. In addition, through selection of the proportions of Ga versus In and S versus Se, the bandgap of CuInxGa1–xSySe2–y can be tailored to a value between 1.0 and 2.4 eV, thus making it possible to fabricate cells containing high and/or graded bandgaps.

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Spray CVD for Making Solar-Cell Absorber Layers

Spray CVD combines the advantages of metalorganic CVD and spray pyrolysis. Spray chemical vapor deposition (spray CVD) processes of a special type have been investigated for use in making CuInS2 absorber layers of thin-film solar photovoltaic cells from either of two subclasses of precursor compounds: [(PBu3) 2Cu(SEt)2In(SEt)2] or [(PPh3)2Cu(SEt)2 In(SEt)2] . CuInS2 is a member of the class of chalcopyrite semiconductors described in the immediately preceding article. [(PBu3)2Cu(SEt)2In(SEt)2] and [(PPh3)2 Cu(SEt)2In(SEt)2] are members of the class of single-source precursors also described in the preceding article.

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Making Ternary Quantum Dots From Single-Source Precursors

Relative to a prior process, this process is simpler and safer. A process has been devised for making ternary (specifically, CuInS2) nanocrystals for use as quantum dots (QDs) in a contemplated next generation of highefficiency solar photovoltaic cells. The process parameters can be chosen to tailor the sizes (and, thus, the absorption and emission spectra) of the QDs.

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Increasing Durability of Flame-Sprayed Strain Gauges

Low-oxygen heat treatments and internal platinum oxygen-diffusion barriers extend lifetimes. Thermally sprayed dielectric ceramic coatings are the primary means of attaching strain and temperature gauges to hot-section rotating parts of turbine engines. As hot-section temperatures increase, lifetimes of installed gauges decrease, and seldom exceed one hour above 2,000 °F ( ≈1,100 °C). Advanced engine components are expected to operate at temperatures approaching 2,200 °F ( ≈1,200 °C), and the required high-temperature lifetime is 10 hours minimum.

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Multifunctional, High-Temperature Nanocomposites

Electrical and thermal conductivities increase with proportions of nanotubes. In experiments conducted as part of a continuing effort to incorporate multifunctionality into advanced composite materials, blends of multi-walled carbon nanotubes and a resin denoted “PETI-330” (wherein “PETI” is an abbreviation for “phenylethynyl- terminated imide”) were prepared, characterized, and fabricated into moldings. PETI-330 was selected as the matrix resin in these experiments because of its low melt viscosity (<10 poise at a temperature of 280 °C), excellent melt stability (lifetime >2 hours at 280 °C), and high temperature performance (>1,000 hours at 288 °C). The multi-walled carbon nanotubes (MWCNTs), obtained from the University of Kentucky, were selected because of their electrical and thermal conductivity and their small diameters. The purpose of these experiments was to determine the combination of thermal, electrical, and mechanical properties achievable while still maintaining melt processability.

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Multilayer Impregnated Fibrous Thermal Insulation Tiles

Temperature rises are limited by transpiration cooling. The term “secondary polymer layered impregnated tile” (“SPLIT”) denotes a type of ablative composite-material thermal- insulation tiles having engineered, spatially non-uniform compositions. The term “secondary” refers to the fact that each tile contains at least two polymer layers wherein endothermic reactions absorb considerable amounts of heat, thereby helping to prevent overheating of an underlying structure. These tiles were invented to afford lighter-weight alternatives to the reusable thermal-insulation materials heretofore variously used or considered for use in protecting the space shuttles and other spacecraft from intense atmospheric- entry heating. Tiles of this type could also be useful on Earth as relatively lightweight components of fire-retardant structures.

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Accounting for Uncertainties in Strengths of SiC MEMS Parts

Fracture strength of a part can be predicted as one statistical distribution. A methodology has been devised for accounting for uncertainties in the strengths of silicon carbide structural components of microelectromechanical systems (MEMS). The methodology enables prediction of the probabilistic strengths of complexly shaped MEMS parts using data from tests of simple specimens. This methodology is intended to serve as a part of a rational basis for designing SiC MEMS, supplementing methodologies that have been borrowed from the art of designing macroscopic brittle material structures.

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