More stories

  • in

    Turning up the heat on next-generation semiconductors

    The scorching surface of Venus, where temperatures can climb to 480 degrees Celsius (hot enough to melt lead), is an inhospitable place for humans and machines alike. One reason scientists have not yet been able to send a rover to the planet’s surface is because silicon-based electronics can’t operate in such extreme temperatures for an extended period of time.For high-temperature applications like Venus exploration, researchers have recently turned to gallium nitride, a unique material that can withstand temperatures of 500 degrees or more.The material is already used in some terrestrial electronics, like phone chargers and cell phone towers, but scientists don’t have a good grasp of how gallium nitride devices would behave at temperatures beyond 300 degrees, which is the operational limit of conventional silicon electronics.In a new paper published in Applied Physics Letters, which is part of a multiyear research effort, a team of scientists from MIT and elsewhere sought to answer key questions about the material’s properties and performance at extremely high temperatures.  They studied the impact of temperature on the ohmic contacts in a gallium nitride device. Ohmic contacts are key components that connect a semiconductor device with the outside world.The researchers found that extreme temperatures didn’t cause significant degradation to the gallium nitride material or contacts. They were surprised to see that the contacts remained structurally intact even when held at 500 degrees Celsius for 48 hours.Understanding how contacts perform at extreme temperatures is an important step toward the group’s next goal of developing high-performance transistors that could operate on the surface of Venus. Such transistors could also be used on Earth in electronics for applications like extracting geothermal energy or monitoring the inside of jet engines.“Transistors are the heart of most modern electronics, but we didn’t want to jump straight to making a gallium nitride transistor because so much could go wrong. We first wanted to make sure the material and contacts could survive, and figure out how much they change as you increase the temperature. We’ll design our transistor from these basic material building blocks,” says John Niroula, an electrical engineering and computer science (EECS) graduate student and lead author of the paper.His co-authors include Qingyun Xie PhD ’24; Mengyang Yuan PhD ’22; EECS graduate students Patrick K. Darmawi-Iskandar and Pradyot Yadav; Gillian K. Micale, a graduate student in the Department of Materials Science and Engineering; senior author Tomás Palacios, the Clarence J. LeBel Professor of EECS, director of the Microsystems Technology Laboratories, and a member of the Research Laboratory of Electronics; as well as collaborators Nitul S. Rajput of the Technology Innovation Institute of the United Arab Emirates; Siddharth Rajan of Ohio State University; Yuji Zhao of Rice University; and Nadim Chowdhury of Bangladesh University of Engineering and Technology.Turning up the heatWhile gallium nitride has recently attracted much attention, the material is still decades behind silicon when it comes to scientists’ understanding of how its properties change under different conditions. One such property is resistance, the flow of electrical current through a material.A device’s overall resistance is inversely proportional to its size. But devices like semiconductors have contacts that connect them to other electronics. Contact resistance, which is caused by these electrical connections, remains fixed no matter the size of the device. Too much contact resistance can lead to higher power dissipation and slower operating frequencies for electronic circuits.“Especially when you go to smaller dimensions, a device’s performance often ends up being limited by contact resistance. People have a relatively good understanding of contact resistance at room temperature, but no one has really studied what happens when you go all the way up to 500 degrees,” Niroula says.For their study, the researchers used facilities at MIT.nano to build gallium nitride devices known as transfer length method structures, which are composed of a series of resistors. These devices enable them to measure the resistance of both the material and the contacts.They added ohmic contacts to these devices using the two most common methods. The first involves depositing metal onto gallium nitride and heating it to 825 degrees Celsius for about 30 seconds, a process called annealing.The second method involves removing chunks of gallium nitride and using a high-temperature technology to regrow highly doped gallium nitride in its place, a process led by Rajan and his team at Ohio State. The highly doped material contains extra electrons that can contribute to current conduction.“The regrowth method typically leads to lower contact resistance at room temperature, but we wanted to see if these methods still work well at high temperatures,” Niroula says.A comprehensive approachThey tested devices in two ways. Their collaborators at Rice University, led by Zhao, conducted short-term tests by placing devices on a hot chuck that reached 500 degrees Celsius and taking immediate resistance measurements.At MIT, they conducted longer-term experiments by placing devices into a specialized furnace the group previously developed. They left devices inside for up to 72 hours to measure how resistance changes as a function of temperature and time.Microscopy experts at MIT.nano (Aubrey N. Penn) and the Technology Innovation Institute (Nitul S. Rajput) used state-of-the-art transmission electron microscopes to see how such high temperatures affect gallium nitride and the ohmic contacts at the atomic level.“We went in thinking the contacts or the gallium nitride material itself would degrade significantly, but we found the opposite. Contacts made with both methods seemed to be remarkably stable,” says Niroula.While it is difficult to measure resistance at such high temperatures, their results indicate that contact resistance seems to remain constant even at temperatures of 500 degrees, for around 48 hours. And just like at room temperature, the regrowth process led to better performance.The material did start to degrade after being in the furnace for 48 hours, but the researchers are already working to boost long-term performance. One strategy involves adding protective insulators to keep the material from being directly exposed to the high-temperature environment.Moving forward, the researchers plan to use what they learned in these experiments to develop high-temperature gallium nitride transistors.“In our group, we focus on innovative, device-level research to advance the frontiers of microelectronics, while adopting a systematic approach across the hierarchy, from the material level to the circuit level. Here, we have gone all the way down to the material level to understand things in depth. In other words, we have translated device-level advancements to circuit-level impact for high-temperature electronics, through design, modeling and complex fabrication. We are also immensely fortunate to have forged close partnerships with our longtime collaborators in this journey,” Xie says.This work was funded, in part, by the U.S. Air Force Office of Scientific Research, Lockheed Martin Corporation, the Semiconductor Research Corporation through the U.S. Defense Advanced Research Projects Agency, the U.S. Department of Energy, Intel Corporation, and the Bangladesh University of Engineering and Technology.Fabrication and microscopy were conducted at MIT.nano, the Semiconductor Epitaxy and Analysis Laboratory at Ohio State University, the Center for Advanced Materials Characterization at the University of Oregon, and the Technology Innovation Institute of the United Arab Emirates. More

  • in

    Communications system achieves fastest laser link from space yet

    In May 2022, the TeraByte InfraRed Delivery (TBIRD) payload onboard a small CubeSat satellite was launched into orbit 300 miles above Earth’s surface. Since then, TBIRD has delivered terabytes of data at record-breaking rates of up to 100 gigabits per second — 100 times faster than the fastest internet speeds in most cities — via an optical communication link to a ground-based receiver in California. This data rate is more than 1,000 times higher than that of the radio-frequency links traditionally used for satellite communication and the highest ever achieved by a laser link from space to ground. And these record-setting speeds were all made possible by a communications payload roughly the size of a tissue box.

    MIT Lincoln Laboratory conceptualized the TBIRD mission in 2014 as a means of providing unprecedented capability to science missions at low cost. Science instruments in space today routinely generate more data than can be returned to Earth over typical space-to-ground communications links. With small, low-cost space and ground terminals, TBIRD can enable scientists from around the world to fully take advantage of laser communications to downlink all the data they could ever dream of.

    Designed and built at Lincoln Laboratory, the TBIRD communications payload was integrated onto a CubeSat manufactured by Terran Orbital as part of NASA’s Pathfinder Technology Demonstrator program. NASA Ames Research Center established this program to develop a CubeSat bus (the “vehicle” that powers and steers the payload) for bringing science and technology demonstrators into orbit more quickly and inexpensively. Weighing approximately 25 pounds and the size of two stacked cereal boxes, the CubeSat was launched into low-Earth orbit (LEO) aboard Space X’s Transporter-5 rideshare mission from Cape Canaveral Space Force Station in Florida in May 2022. The optical ground station is located in Table Mountain, California, where most weather takes place below the mountain’s summit, making this part of the sky relatively clear for laser communication. This ground station leverages the one-meter telescope and adaptive optics (to correct for distortions caused by atmospheric turbulence) at the NASA Jet Propulsion Laboratory Optical Communications Telescope Laboratory, with Lincoln Laboratory providing the TBIRD-specific ground communications hardware.

    “We’ve demonstrated a higher data rate than ever before in a smaller package than ever before,” says Jade Wang, the laboratory’s program manager for the TBIRD payload and ground communications and assistant leader of the Optical and Quantum Communications Technology Group. “While sending data from space using lasers may sound futuristic, the same technical concept is behind the fiber-optic internet we use every day. The difference is that the laser transmissions are taking place in the open atmosphere, rather than in contained fibers.”

    From radio waves to laser light

    Whether video conferencing, gaming, or streaming movies in high definition, you are using high-data-rate links that run across optical fibers made of glass (or sometimes plastic). About the diameter of a strand of human hair, these fibers are bundled into cables, which transmit data via fast-traveling pulses of light from a laser or other source. Fiber-optic communications are paramount to the internet age, in which large amounts of data must be quickly and reliably distributed across the globe every day.

    For satellites, however, a high-speed internet based on laser communications does not yet exist. Since the beginning of spaceflight in the 1950s, missions have relied on radio frequencies to send data to and from space. Compared to radio waves, the infrared light employed in laser communications has a much higher frequency (or shorter wavelength), which allows more data to be packed into each transmission. Laser communications will enable scientists to send 100 to 1,000 times more data than today’s radio-frequency systems — akin to our terrestrial switch from dial-up to high-speed internet.

    From Earth observation to space exploration, many science missions will benefit from this speedup, especially as instrument capabilities advance to capture larger troves of high-resolution data, experiments involve more remote control, and spacecraft voyage further from Earth into deep space.  

    However, laser-based space communication comes with several engineering challenges. Unlike radio waves, laser light forms a narrow beam. For successful data transmission, this narrow beam must be pointed precisely toward a receiver (e.g., telescope) located on the ground. And though laser light can travel long distances in space, laser beams can be distorted because of atmospheric effects and weather conditions. This distortion causes the beam to experience power loss, which can result in data loss.

    For the past 40 years, Lincoln Laboratory been tackling these and related challenges through various programs. At this point, these challenges have been reliably solved, and laser communications is rapidly becoming widely adopted. Industry has begun a proliferation of LEO cross-links using laser communications, with the intent to enhance the existing terrestrial backbone, as well as to provide a potential internet backbone to serve users in rural locations. Last year, NASA launched the Laser Communications Relay Demonstration (LCRD), a two-way optical communications system based on a laboratory design. In upcoming missions, a laboratory-developed laser communications terminal will be launched to the International Space Station, where the terminal will “talk” to LCRD, and support Artemis II, a crewed program that will fly by the moon in advance of a future crewed lunar landing.

    “With the expanding interest and development in space-based laser communications, Lincoln Laboratory continues to push the envelope of what is possible,” says Wang. “TBIRD heralds a new approach with the potential to further increase data rate capabilities; shrink size, weight, and power; and reduce lasercom mission costs.”

    One way that TBIRD aims to reduce these costs is by utilizing commercial off-the-shelf components originally developed for terrestrial fiber-optic networks. However, terrestrial components are not designed to survive the rigors of space, and their operation can be impacted by atmospheric effects. With TBIRD, the laboratory developed solutions to both challenges.

    Commercial components adapted for space

    The TBIRD payload integrates three key commercial off-the-shelf components: a high-rate optical modem, a large high-speed storage drive, and an optical signal amplifier.

    All these hardware components underwent shock and vibration, thermal-vacuum, and radiation testing to inform how the hardware might fare in space, where it would be subject to powerful forces, extreme temperatures, and high radiation levels. When the team first tested the amplifier through a thermal test simulating the space environment, the fibers melted. As Wang explains, in vacuum, no atmosphere exists, so heat gets trapped and cannot be released by convection. The team worked with the vendor to modify the amplifier to release heat through conduction instead.

    To deal with data loss from atmospheric effects, the laboratory developed its own version of Automatic Repeat Request (ARQ), a protocol for controlling errors in data transmission over a communications link. With ARQ, the receiver (in this case, the ground terminal) alerts the sender (satellite) through a low-rate uplink signal to re-transmit any block of data (frame) that has been lost or damaged.

    “If the signal drops out, data can be re-transmitted, but if done inefficiently — meaning you spend all your time sending repeat data instead of new data — you can lose a lot of throughput,” explains TBIRD system engineer Curt Schieler, a technical staff member in Wang’s group. “With our ARQ protocol, the receiver tells the payload which frames it received correctly, so the payload knows which ones to re-transmit.”

    Another aspect of TBIRD that is new is its lack of a gimbal, a mechanism for pointing the narrow laser beam. Instead, TBIRD relies on a laboratory-developed error-signaling concept for precision body pointing of the spacecraft. Error signals are provided to the CubeSat bus so it knows how exactly to point the body of the entire satellite toward the ground station. Without a gimbal, the payload can be even further miniaturized.

    “We intended to demonstrate a low-cost technology capable of quickly downlinking a large volume of data from LEO to Earth, in support of science missions,” says Wang. “In just a few weeks of operations, we have already accomplished this goal, achieving unprecedented transmission rates of up to 100 gigabits per second. Next, we plan to exercise additional features of the TBIRD system, including increasing rates to 200 gigabits per second, enabling the downlink of more than 2 terabytes of data — equivalent to 1,000 high-definition movies — in a single five-minute pass over a ground station.”

    Lincoln Laboratory developed the TBIRD mission and technology in partnership with NASA Goddard Space Flight Center. More