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At least 253 records · Page 14

Double-Side Cooled 1.2kV, 300A SiC MOSFET Phase-leg Modules for 200 kW, > 100 kW/L Traction Inverters

The packaging of a double-side cooled 1.2 kV, 149 A SiC phase-leg modules has been reported in recent years for making 100 kW, 100 kW/L traction inverters. Each phase-leg module consists of two SiC MOSFETs, one per switch position. Six of the phase-leg modules are assembled into a segmented inverter configuration to meet the power and power density requirement. In this work, the layout of the phase-leg module was redesigned to include four of the SiC MOSFETs, two per switch position, with the aim of doubling the power to 200 kW and increasing the power density beyond 100 kW/L, but with only a 10.25% footprint increase. Key features of the packaging technology developed in the previous work were implemented in the current work, which include silver sintering for chip bonding and porous silver inter-posts for bonding device source pads to substrate. Parasitic extraction simulation showed that the four-chip module has a low parasitic inductance of 4.7 nH, like the two-chip module. Static characterization of the four-chip prototypes showed a low average on-resistance of 9 mΩ and a low average leakage current of 5 nA at Vds of 1.2 kV.

Zhang, Zichen↗

Self-Sacrificial Template Synthesis of Fe-N-C Catalysts with Dense Active Sites Deposited on A Porous Carbon Network for High Performance in PEMFC

In this study, iron-nitrogen-carbon (Fe-N-C) single-atom catalysts are promising sustainable alternatives to the costly and scarce platinum (Pt) to catalyze the oxygen reduction reactions (ORR) at the cathode of proton exchange membrane fuel cells (PEMFCs). However, Fe-N-C cathodes for PEMFC are made thicker than Pt/C ones, in order to compensate for the lower intrinsic ORR activity and site density of Fe-N-C materials. The thick electrodes are bound with mass transport issues that limit their performance at high current densities, especially in H 2 /air PEMFCs. Practical Fe-N-C electrodes must combine high intrinsic ORR activity, high site density, and fast mass transport. Herein, it has achieved an improved combination of these properties with a Fe-N-C catalyst prepared via a two-step synthesis approach, constructing first a porous zinc-nitrogen-carbon (Zn-N-C) substrate, followed by transmetallating Zn by Fe via chemical vapor deposition. A cathode comprising this Fe-N-C catalyst has exhibited a maximum power density of 0.53 W cm -2 in H 2 /air PEMFC at 80 °C. The improved power density is associated with the hierarchical porosity of the Zn-N-C substrate of this work, which is achieved by epitaxial growth of ZIF-8 onto g-C 3 N 4 , leading to a micro-mesoporous substrate.

25 ENERGY STORAGE↗

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation represents a report of accomplishments during FY 2024 and is prepared for 2024 DOE VTO Annual Merit Review. The project goal is identifying pathways enabling high-performance, compact, and reliable integrated electric drives and facilitation of achieving DOE 2025 target of 33 kW/L system power density for an electric traction drive through support of other EDT consortium members in design and development of thermal management systems for their respective integrated drive concepts. Specific objectives are: 1) research and evaluation of motor-integrated power electronics packaging technologies and thermal management approaches; 2) explore novel materials and manufacturing options (3D printing with thermally enhanced polymers or ceramic materials) for key thermal management system components; 3) develop thermal management system and its sub-components to enable integrated electric drive DOE power density targets in collaboration with project partners; 4) support activities of DOE's Electric Drive Technologies (EDT) consortium members, Oak Ridge National Laboratory (ORNL), University of Wisconsin and Georgia Tech research teams in thermal management component design and thermal modeling of their integrated traction drives.

ADVANCED PROPULSION SYSTEMS↗

Experimental Characterization of High-Surface Area Thermal Energy Storage

There is growing interest in energy storage technologies due to the expansion of renewable energy sources that are inherently intermittent and the increasing frequency of extreme weather events that disturb the power grid. Power consumption in buildings makes up approximately 76% of all electricity usage on the grid and is primarily used for thermal applications such as space conditioning, hot water, and cooking. This makes thermal energy storage (TES) an ideal solution for many of these applications. Many TES technologies rely on latent energy storage, which utilizes the melting/solidification of phase change materials (PCM) to store energy. Typically, TES designs suffer from low power density due to their low inherent thermal conductivity. This limitation makes the deployment of TES in active applications difficult as the ease of access to energy is essential for effective use. Common routes for improving power density include high thermal conductivity additives or extended features such as fins that increase cost. This study presents an alternative approach to improving performance through increasing the overall surface area to volume ratio of the device, to increase the available area for convection to occur between the working fluid and PCM. In the study a commercial PCM was selected with a transition temperature ideal for space heating applications. The heat exchanger design utilizes a unique application of triply periodic minimal surfaces (TPMS) for macro-encapsulation of the PCM. The use of TPMS for heat exchangers has been growing in interest due to their high-surface area to volume ratios, which were previously unmanufacturable until the development of additive manufacturing. A modular system was designed and manufactured with a stereolithography resin printing system that is then backfilled with PCM. An experiment test set-up is designed to test the charge and discharge performance of the thermal storage using a conditioned air stream. The pressure drop of the design is tested across a variety of flow rates. When compared to existing experimental data within literature, there is excellent agreement based on the Reynolds number at similar hydraulic diameters. Several inlet temperatures are tested at consistent temperature differences from the phase change temperature for both charging and discharging. Additionally, the volumetric flow rate is varied for each temperature set point. It was found that increasing flow rate had diminishing returns in reducing the overall charge time of the TES. The temperature delta from the melting temperature was the primary contributor to the change in average heat flux with limited variation in average heat transfer rate between charging and discharging at similar inlet temperatures and flow rates. The TPMS heat exchanger design has a high air-side pressure drop but it provides high heat transfer rates. This helps maintain a high outlet temperature during discharge, which is important to thermal comfort applications. The design, manufacturing, and experimental characterization of the TES device will be presented as part of this study.

25 ENERGY STORAGE↗

System and method for high power diode based additive manufacturing

The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material (PM) forming a substrate. The system uses a first optical subsystem to generate an optical signal comprised of electromagnetic (EM) radiation sufficient to melt or sinter a PM of the substrate. The first optical subsystem is controlled to generate a plurality of different power density levels, with a specific one being selected based on a specific PM forming a powder bed being used to form a 3D part. At least one processor controls the first optical subsystem and adjusts a power density level of the optical signal, taking into account a composition of the PM. A second optical subsystem receives the optical signal from the first optical subsystem and controls the optical signal to help facilitate melting of the PM in a layer-by-layer sequence of operations.

El-Dasher, Bassem S.↗

Non-uniform longitudinal current density induced power saturation in GaAs-based high power diode lasers

The output power of modern 975 nm GaAs-based broad area diode lasers is limited by increasing carrier and photon losses at high bias. Here, we use experiment and one-dimensional calculations on these devices to reveal that higher current densities (and hence higher local recombination rates and higher losses) arise near the front facet due to spatial hole burning and that the non-uniformity is strongly affected by laser geometry, which is more severe for longer resonators and less severe for higher front facet reflectivity. Specifically, we use devices with a segmented p-contact to directly measure the current distribution along the resonator and compare this with laser simulation. Devices with a 6 mm resonator show 29% more current at the front than back, twice as large as the 15% current non-uniformity in devices with a 3 mm resonator. In contrast, increased front facet reflectivity (20% rather than 0.8%) is shown to almost halve the current non-uniformity from 29% to 18% in devices with a 6 mm resonator and reduces power saturation. Although the magnitude of current non-uniformity in experiment and theory is broadly consistent, in experiment, an additional divergence is seen in current flow (and hence recombination rate) near the facets, and earlier power saturation occurs. Finally, we discuss the possible saturation mechanisms that are not included in the simulation.

47 OTHER INSTRUMENTATION↗

Multiphysics Running-In Simulations for Pebble-Bed Reactors with Griffin

Griffin, a Multiphysics Object-Oriented Simulation Environment (MOOSE)–based application targeting transient modeling of advanced reactors, has been used recently to model pebble-bed reactors (PBRs). The modeling effort has focused thus far on equilibrium core calculations. A new capability to simulate the running-in phase of PBR operation has been added to Griffin. This work demonstrates the new capability with a coupled multiphysics running-in simulation. Griffin computes power densities in the core at each time step of the running-in simulation and passes these to Pronghorn, which models fluid flow and heat transfer to calculate pebble surface temperatures. These surface temperatures are used along with the power densities in a heat conduction model to compute average fuel and moderator temperatures, which are passed back to Griffin and accounted for with temperature-dependent cross sections. This work also describes a novel methodology for determining appropriate pebble feed rates and control rod positioning during the running-in simulation. Furthermore, the RZ-geometry model used in this work requires minimal computational resources and can be used for optimization and uncertainty studies in future works.

Griffin↗

Improving Performance and Durability of Low Temperature Direct Ammonia Fuel Cells: Effect of Backpressure and Oxygen Reduction Catalysts

Low temperature direct ammonia fuel cells (DAFCs) are attractive for transportation applications. The primary obstacle to their commercial use is their low performance and poor durability. In the present work, we focus on improving DAFCs performance and durability by examining the effect of operating backpressure and oxygen reduction reaction (ORR) catalysts such as Acta 4020, Pd/C and Pt/C. DAFCs with Acta 4020 cathode can reach a peak power density of 390 mW cm -2 which is among the best reported performance, but they can be operated for a period of 11 h at 300 mA cm -2 . DAFCs with Pd/C cathode offer a moderate performance with a peak power density of 304 mW cm -2 , but has a much improved durability - a continuous operation for up to 36 h with a slow decay rate of ~1 mV h -1 at 300 mA cm -2 . In addition, the degradation pathways for DAFCs with Pd/C cathode are probed by characterizing the initial and final electrodes by XPS, suggesting that cathodic Pd dissolution occurs during the durability test.

Electrochemistry↗

VTO 2022 Annual Progress Report: Vertical GaN Device Development

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than $\$$6/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of $\$$2.7/kW. New materials such as wide bandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective co optimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

33 ADVANCED PROPULSION SYSTEMS↗

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation represents a report of accomplishments during FY 2022 and is prepared for 2022 DOE VTO Annual Merit Review. The project goal is facilitation of achieving DOE 2025 target of 33 kW/L system power density for an electric traction drive through support of other EDT consortium members in design and development of thermal management systems for their respective integrated drive concepts. Namely, identifying pathways enabling high-performance, compact, and reliable integrated electric drives. Specific objectives are: 1) Research and evaluation of motor-integrated power electronics packaging technologies and thermal management approaches. 2) Development of thermal management system and its sub-components to enable integrated electric drive DOE power density targets in collaboration with project partners. 3) Supporting activities of DOE's Electric Drive Technologies (EDT) consortium members, Oak Ridge National Laboratory (ORNL) and University of Wisconsin research teams in thermal management component design and thermal modeling of their integrated traction drives. 4) Identifying candidate driveline fluids suitable for direct cooling of traction-drive components and high-voltage power electronics and evaluate their convective cooling performance.

ADVANCED PROPULSION SYSTEMS↗

2021 Annual Progress Report: Vertical GaN Device Development

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than 6 dollars/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of 2.7 dollars/kW. New materials such as wide-bandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective co-optimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

33 ADVANCED PROPULSION SYSTEMS↗

Ultrasonic degradation of GenX (HFPO-DA) – Performance comparison to PFOA and PFOS at high frequencies

Sonolytic degradation kinetics of hexafluoropropylene oxide-dimer acid (HFPO-DA or GenX) were studied for the first time at four high ultrasonic frequencies (375, 580, 860 and 1,140kHz) and three power densities (200, 300 and 400W/L), and compared to the degradation of previously studied perfluorooctanoic acid (PFOA) and perfluorooctanesulfonic acid (PFOS). The frequency of 580kHz displayed the highest degradation of all three PFAS tested. Within each frequency, the degradation performance increased consistently with increasing power density. Degradation rates were highest for GenX over PFOA to PFOS (k GenX = 0.0501 min -1 , k PFOA = 0.0444 min -1 , k PFOS 0.0153 min -1 ), which is in direct agreement with their reported thermal stability (PFOS > PFOA > GenX). No known by-product formation as expected from the literature on truncation mechanism was detected in the samples (i.e. shorter chain carboxylic acid PFAS). Further, fluorine mass balance experiments at 580kHz and 400W/ L confirmed that GenX defluorinated fastest among the three tested PFAS and had lowest loss of fluorine in the mass balance. Degradation experiments with a mixture of all three PFAS displayed lower degradation rates than the individual experiments, where PFOA exhibited the largest reduction in degradation rate (by 31%), followed by GenX (by 19%), and finally by PFOS (by 17%). Overall, our study demonstrates that ultrasound can provide effective destruction of different PFAS (70-90% fluorine from mitigated PFAS was detected as inorganic fluoride) with a similar energy demand to alternative PFAS treatment methods reported in literature.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Multiphysics simulation of TRISO fuel compacts and the effects of homogenization on silver release predictions

This work studies the impact of explicit and homogenized modeling approaches on the multiphysics simulation of TRistructural ISOtropic (TRISO) fuel compacts in prismatic High Temperature Gas Reactors (HTGRs) and the silver release predictions. TRISO fuel compacts exhibit complex double heterogeneity that significantly affects heat conduction, neutron transport, and fission products release. In this work, we use Cardinal, a multiphysics tool based on the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to couple neutron transport and heat conduction. OpenMC is used for neutron transport and the MOOSE heat transfer module is used for the heat conduction. Then, we use BISON for the silver release predictions. Two different modeling approaches—explicit modeling of individual TRISO particles and homogenized representation using effective thermal properties—are compared at high TRISO packing fractions (20% and 40%) across varying power densities. Results demonstrate that homogenization significantly under-predicts peak temperatures, for the case of high power/TRISO, there is a difference of 83.73 K in the maximum temperature. Additionally, homogenization underestimates the silver release predictions compared to explicit modeling. Specifically, the temperature and power density differences lead to significant differences in silver release predictions. This work demonstrates the importance of accurately modeling heterogeneity of the TRISO particles to reliably predict fission product release and assess reactor safety margins.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Investigation of startup, performance and cycling of a residential furnace integrated with micro-tubular flame-assisted fuel cells for micro-combined heat and power

Solid Oxide Fuel Cells (SOFCs) offer advantages for micro-Combined Heat and Power (μCHP), but currently suffer from slow startup (>1 h) and limited thermal cycling which reduces the applications, energy savings and economics. In this work, a micro-Tubular SOFC stack is integrated into a residential furnace to create a micro-Tubular Flame-assisted Fuel Cell (mT-FFC) μCHP system. A high power density of 202 mW cm -2 is reported operating in synthesis gas generated from fuel-rich combustion of natural gas/air. Unlike previous reports, instabilities in the polarization are attributed to low temperature of the oxygen reduction reaction at the cathode. The mT-FFC stack achieved peak power density in 6 min after ignition. 200 thermal cycles at an average heating rate of 215 °C.min -1 and average cooling rate of 176 °C.min -1 were conducted and a low degradation rate of 0.0325 V per 100 cycles per fuel cell was achieved. Low NO x emissions (10 ppm) and high combined efficiency is reported.

25 ENERGY STORAGE↗

Coal-derived electrically conductive asphalt pavements for snow/ice melting: From laboratory to field

Timely removal of ice and snow from roads is critical to safe, fast, and uninterrupted transportation networks in cold regions. Constructing electrically conductive asphalt pavements to melt the ice and snow on the roads through resistive eating is an emerging alternative technology to traditional snow/ice removal approaches such as utilizing snowplow machines and deicing chemicals. Carbon-based fibers and fillers including carbon fiber and graphite have been widely reported to make electrically conductive hot mix asphalt mixtures for pavement snow/ice-melting applications. This study aimed to develop and demonstrate a novel type of electrically conductive asphalt pavements for snow/ice-melting, which utilizes electrically conductive cold mix asphalt (CMA) mixtures incorporating coal-derived carbon-based coke aggregate as resistive heating elements. Both laboratory experiments and field tests were conducted to investigate the electrical, mechanical, and thermal properties of such electrically conductive asphalt mixtures and pavements. The laboratory experiment results indicated that the electrically conductive CMA mixtures incorporating coke aggregate had sufficiently high electrical conductivity and satisfactory mechanical performance and the pavement prototype slab utilizing a thin layer of such CMA mixtures could successfully raise the pavement surface temperatures to 8.3–11.7 °C rom a low temperature of –5 °C with an input power density of 473 W/m 2 . The field test results showed that the full-scale coal-derived electrically conductive asphalt pavements were able to increase the pavement surface temperatures when electricity was applied, but the magnitude of temperature increase was highly dependent on the power density. Furthermore, it is promising to use coke aggregate to construct coal-derived electrically conductive asphalt pavements for snow/ice melting.

36 MATERIALS SCIENCE↗

Characteristics of Oxygen Electrode Supported Reversible Solid Oxide Cells

Oxygen-electrode-supported solid oxide cells (OESCs) have potential advantages over fuel-electrode-supported cells, including reduced fuel-electrode concentration polarization, better oxygen electrode current collection, and flexibility in the fuel electrode choice. However, there are serious drawbacks including the difficulty of co- firing the oxygen electrode and electrolyte, and oxygen electrode concentration polarization. This paper explores the characteristics of OESCs with La 0.8 Sr 0.2 MnO 3-δ -Zr 0.92 Y 0.16 O 2-δ (LSM-YSZ) electrode-support enhanced by SrTi 0.3 Fe 0.6 Co 0.1 O 3-δ (STFC) infiltration, thin YSZ electrolyte, and SrTi 0.3 Fe 0.7 O 3-δ (STF) fuel electrodes. Here, the STFC infiltration increases fuel cell maximum power density by > 1.5 times and electrolysis current density (at 1.3 V) by > 2 times. Cell performance in pure oxygen is compared to that in air, exploring a possible reversible solid oxide cell system configuration where oxygen produced during electrolysis is stored and subsequently used during fuel cell operation. The fuel cell maximum power density is increased from 0.88 W cm -2 in air to 1.37 W cm -2 in oxygen, with limiting current increased from 1.7 to >5.6 A cm -2 ; the electrolysis performance is essentially unchanged, probably because the electrode air becomes enriched with oxygen during electrolysis.

25 ENERGY STORAGE↗

Self-Powered Autonomous Sensing System for Arctic Ocean using a Frequency-multiplied Cylindrical Triboelectric Nanogenerator

An autonomous sensing system for collecting environmental observations in the Arctic region is critical for the estimation and prediction of climate change. Ocean waves are a great source of energy for these sensing systems but there has been limited research done on small-scale energy harvesting applications in the Arctic Ocean (subsea or surface). The available wave energy in the Arctic Ocean is lower than the typical ocean wave energy due to the low wave frequency, height, and operating months. Although the available wave energy depends on the specific location in the Arctic Ocean, the wave height decreases everywhere during the winter (Jan-March) [1]. Our target location in this work is the Beaufort and Chukchi Seas, which are ice covered for about 195 days per year leaving only a few months (June-November) for wave energy harvesting [2]. During these few months, the average wave frequency is 0.2 Hz and the most common wave frequency is around 0.15 Hz. Many energy harvesting methods are unsuitable for use in the Arctic Ocean because of to the cold temperature, low wave frequency, and low wave height. Triboelectric nanogenerators (TENG) are one of the few energy harvesting methods that excel in these conditions. Zhong et al. [3] designed a stacked pendulum-structured TENG for low-frequency ocean wave energy and reported the device generated a peak power density of 11.2 W/m3 under the low wave frequency of 0.2 Hz. The autonomous sensing system we developed for the Arctic Ocean, the Arctic-TENG, is based on a frequency-multiplied cylindrical TENG (FMC-TENG) which is an optimized TENG configuration for Arctic Ocean conditions due to the high power density under low-frequency wave conditions [4]. Figure 1 shows an FMC-TENG with multiple pairs of free-standing triboelectric-layer mode materials (Aluminum and FEP). The mass and magnet attached to the rotor store gravitational potential energy which is released as kinetic energy when the potential energy overcomes the repulsive magnetic force generated by the opposing magnet attached to the stator. This force unbalance triggers a sudden rotation and swinging motion of the mass which increases the angular velocity of the system and therefore enhances the output power of the TENG system. The main components of the Arctic-TENG are a 3D-printed rotor and stator, electric and dielectric material adhesive tape, and bearings. All these materials were cold-soaked and tested at -40 °C in a chest freezer. Both the 3D-printed parts and adhesives were confirmed to have a minimal effect from the cold temperature. Multiple bearings were tested and the starting torque of each one was compared both at room temperature and -40 °C. The bearing with the lowest starting torque at -40 °C was selected for use in the Arctic-TENG. The Arctic-TENG was tested using an out-of-water motor-driven wave simulator (Figure 2). The wave simulator allows for controlled testing at a wave height of 0.2 m and frequencies between 0.1 Hz to 0.5 Hz. This wave simulator was used for both room temperature and -40 °C testing. The Arctic-TENG generated significantly more power at -40 °C compared to room temperature for each frequency tested. The system stored energy in a supercapacitor via a power management circuit, and the amount of energy stored per day was calculated at different wave frequencies. Based on the conditions at the proposed deployment location (days of non-ice-covered ocean and wave frequency), the amount of stored energy per year from Arctic-TENG was calculated to be enough energy for two transmissions every day. Durability testing was completed on the Arctic-TENG at room temperature to determine the lifetime. The rotor of the Arctic-TENG was attached to a DC motor and spun continuously for several millions of cycles without degradation of the electrical output, demonstrating the feasibility for long-term operation.

Jung, Hyunjun↗

Three-pole wigglers at NSLS-II

The National Synchrotron Light Source-II (NSLS-II) at Brookhaven National Lab (BNL) is a third-generation medium-energy storage ring with 3 GeV and sub-nm-rad horizontal emittance, equipped with a top-off capability of 500 mA. It is designed to deliver an extremely intense photon beam across a wide spectral range, from the far-infrared to the very hard X-ray region. This outstanding performance is achieved through a combination of bending magnets (BM), three-pole wigglers (3 PW), and advanced insertion device (ID) sources. Six three-pole wigglers have been constructed at the NSLS-II IDs Lab. These devices are used to produce broadband radiation with lower angular power density and to monitor the electron beam emittance and energy spread. Here, this paper describes the R&D activities focused on developing the required magnetic and mechanical designs, along with magnetic field optimization and the final magnetic measurement results. It also covers the spectral brightness, flux, power density, spatial and angular output properties of the 3 PWs, including their commissioning results and their effects on the performance of the NSLS-II storage ring.

36 MATERIALS SCIENCE↗