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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 343 records · Page 19

Bio-inspired redox mediated electrolyte for high performance flexible supercapacitor applications over broad temperature domain

For practical supercapacitors, recent advances in electrolytes have diminished long-standing problems such chemical stability, low ionic conductivity and limited electrochemical performance. Herewith, we communicate a facile method to produce anhydrous redox-active Bio-inspired electrolytes for flexible supercapacitors with application over a broad temperature range. The glycerol (Gly) gel electrolyte consists of various fractions of potassium hydroxide (KOH) and redox active unit, i.e., ammonium molybdate, (NH 4 ) 2 MoO 4 (abbreviated as Mo), in the anhydrous state. The doped glycerol matrix acts as a framework that provides a stable gel electrolyte, forming hierarchical pathway for ion diffusion. The developed gel network with Gly-KOH-MoX (X = 3, 5, 10, and 15%, w/w) provides an effective route to carry the ions onto the pores of the electrodes. The supercapacitor with Gly-KOH5-Mo10 gel provides a specific capacitance of 328 F g –1 , and the same device achieved an energy density of 45.6 Wh kg –1 at a power density of 497 W kg –1 . In addition, the supercapacitor maintained extraordinary cyclic robustness and wide temperature tolerance. Thus, the low cost and environmentally benign, cyclic durability of Gly-KOH-Mo makes these gel electrolytes a potential candidate for use in various energy storage devices.

25 ENERGY STORAGE↗

Compact and Low-cost Microinverter for Residential Systems

Concerns regarding climate change from the use of fossil fuels have expedited the growth of renewable energy sources. One such form of renewables, solar energy, is already playing and will continue to play a major role in meeting U.S clean energy targets. Expanding solar power usage in residential networks is a critical step in the decarbonization and clean electricity movement. To achieve a carbon-free grid by promoting solar power to the general public, an aggressive cost reduction in solar power systems is essential. The power density of the equipment used in the solar power system is necessary to solve the challenges of solar power installation. This project aims to research, explore, and assess the possibility of reducing the microinverter cost and volume to achieve the next generation microinverters (NGMs) targets for residential solar photovoltaic applications.

14 SOLAR ENERGY↗

SHOTEAM: Superalloy Heat exchangers Optimized for Temperature Extremes and Additive Manufacturability (Final Technical Report)

UCLA developed an extreme-condition heat exchanger technology targeted to ultra-high efficiency hybrid aviation power cycles. The heat exchanger targeted operation at 50 kW (thermal) at supercritical CO 2 pressures of 80 and 250 bar (1160 and 3626 psi) in hot and cold streams, respectively and at a hot-stream inlet temperature of 800°C (1472°F). A metallic superalloy capable of withstanding high temperature and pressure was used to fabricate a microtube shell-and-tube-based design supplemented with 3D-printed tube augmentations. The optimized design enhanced overall heat transfer while maintaining a small overall form factor and low weight. This class of heat exchanger could dramatically improve efficiency, power density, and cost effectiveness for new hybrid aviation power cycles, thus enabling economically feasible routes to air vehicle propulsion with substantially less CO 2 emissions to the environment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A comprehensive study on two types of supercapacitor composite electrodes comprising MnO 2 and activated carbon nanofibers: Self-supporting membrane and ground powder

Manganese dioxide (MnO 2 )@carbon composites have been attractively considered as electrode materials for supercapacitors (SCs) due to synergistic effects. This work systematically investigated the structure of MnO 2 @carbon nanofiber (CNF) composite electrodes with the different forms of CNFs and the corresponding electrochemical performance of SCs. In brief, novel activated carbon nanofibers were first fabricated by electrospinning the hydroxyl-containing poly(amic acid) solution, and then the preferred CNF material was decorated by MnO 2 crystals in the form of self-supporting membrane and ground powders, respectively. Additionally, the synthesis parameters were investigated and optimized based on the electrochemical performance of SCs. The results reveal that the powdered composite electrode exhibits a higher specific surface area of 501 m 2 g –1 compared to the self-supporting membrane composite electrode under the same conditions, resulting in a promising specific capacity of 214.1 mAh g –1 (770.8 Fg –1 ) in 6M KOH solution at 0.5 A g –1 . In addition, the capacitance of the symmetrical SC device assembled by G-HMC-1:3–80 reaches 179.8 Fg –1 , coupled with an energy density of 24.86 Whkg –1 at 230 Wkg –1 power density. This work provides valuable hints for designing SC composite electrode materials with outstanding performance.

25 ENERGY STORAGE↗

SuperCIC: Enhanced Winding Current Density for Hybrid Windings of Tokamaks

The design is presented for a new approach to cable-in-conduit (SuperCIC) for use in the high-field windings of tokamaks. Two layers of high-field superconductor wires are cabled onto a thin-wall perforated center tube. An overwrap is applied and the cable is inserted as a loose fit into a sheath tube. The sheath tube is drawn down onto the cable to compress the wires onto the center tube and immobilize them. The SuperCIC is then co-wound with a high-strength armor extrusion, which is kerf-cut so that the co-winding onto a coil mandrel can be made without deformation within the armor or the CIC. SuperCIC facilitates hybrid windings, in which subwindings of NbTi are used where B < 7 T, Nb 3 Sn where B < 14 T, and Bi-2212where B > 14 T to minimize superconductor cost. Demount-able splices are used to interconnect layers. A conceptual design has been prepared for a tokamak with aspect ratio A ~ 2.0, magnetic field of 17.4Tat the inner windings and 6.7 T at the plasma,and winding current density ~140 A/mm 2 -sufficient for optimizing the fusion power density in a compact spherical tokamak.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Highly Integrated Wide Bandgap Power Module for Next Generation Plug-In Vehicles (Final Report)

Wide bandgap devices are key enablers for high power density traction inverters. A highly integrated wide bandgap (WBG) power module enables higher temperature operation, higher inverter efficiency and overall smaller die area with the same power delivery. However, it requires careful design of the power module to take advantage of all the superior material properties that silicon carbide (SiC) provides over conventional silicon (Si) Insulated Gate Bipolar Transistor (IGBT) based design. This project developed an efficient and densely packed SiC power module for an automotive traction inverter application. Extensive study was performed to select the best performing SiC die considering a wide range of temperature variation, suitability to integrate into target packaging, robust body diode performance and overall high electrical efficiency. Multiple design ideas were explored to achieve lower stray inductance for both power loop and signal loop, uniform current distribution, compact form factor, and very high thermal performance. The final power module package includes all six inverter switches in the same module (six-pack) with die sintered at both bottom and top surfaces utilizing high performance substrate to achieve high electrical and thermal performance. Two power module variants were developed using 900 V and 1200 V devices for operating at two different high voltage levels (> 600 V HV battery). Both power modules were comprehensively characterized, and high efficiency operation of the inverter was confirmed through analysis. Finally, a complete functional inverter was built with the 1200V power modules using other essential components (HV capacitors, gate driver board, controller board, current sensor, connectors etc.) and tested using GM’s standard test procedure. There are several challenges associated with adopting WBG devices for high voltage operation. In order to assess and mitigate those challenges, GM and subrecipients of this project have conducted multiple detailed studies. This includes phase current reconstruction using integrated Rogowski coil, device junction temperature estimation using on-state gate resistance, modeling and testing the effect of high voltage and fast switching on motor insulation and bearings, partial discharge inception voltage measurement under different environmental conditions. Findings of all these studies are summarized in this report.

33 ADVANCED PROPULSION SYSTEMS↗

Soft-switching, high performance single-phase AC-DC converter

A soft-switching, high-performance single-phase alternating current (AC)-direct current (DC) converter is provided. The AC-DC converter described herein provides a new circuit topology for single-stage, single-phase or multi-phase AC-DC power conversion with power factor correction (PFC) and galvanic isolation using a high-frequency isolation transformer. The AC-DC converter improves power conversion efficiency and power density—two of the most important metrics for a power converter. It achieves soft switching for high frequency switches in the circuit, leading to higher efficiency and lower electromagnetic interference (EMI).

Ayyanar, Rajapandian↗

Design and Verification of An Open-Circuit Electro-Hydraulic Actuator System with An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and two novel-designed electro-hydraulic units (EHU) consisting of a fixed-displacement hydraulic pump and a variable-speed electric motor. Both the novel EHU designs integrate an electric machine and a hydraulic machine in a single unit, featuring compactness and power density. However, they differ for salient aspects such as power and electric machine cooling system. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. The efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The measured efficiency of the system can reach 54% with up to 20kN load and 6kW power level.

42 ENGINEERING↗

Transients using low-high pulsed power in inductively coupled plasmas

Pulsed inductively coupled plasmas (ICPs) are widely deployed in the fabrication of semi-conductor devices. Pulse repetition frequencies (PRFs) of up to tens of kHz are commonly used during plasma etching for the high power densities they generate during the pulse-on period, and for their unique chemistries during the pulse-off period. The use of highly attaching halogen gases produces low electron densities during the pulse-off period, and these low density can result in instabilities, E-H transitions and ignition delays when applying power on the next pulse. To mitigate these possibilities, a low-level power environment could be maintained during “pulse-off” to moderate the minimum plasma density, therefore reducing ignition delays and enhancing plasma stability. In this work, ICPs sustained by 5 kHz pulsed power using Ar/Cl 2 mixtures at 20 mTorr were computationally investigated. For these conditions, the computed electron temperature (T e ) reaches a quasi-steady state during both the high- and low-power excitation. The model predicts that within the electromagnetic skin-depth, T e spikes to a high value during a low-to-high power modulation, and to a low value during a high-to-low power modulation. At the same time, a few cm above the substrate, there is little modulation in T e , as electron power convected from the skin depth disperses in traversing the reactor. Finally, the positive and negative spikes, and convection of transients across the reactors, are functions of power ramping time and gas mixtures.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Field Emission Current Transfer for Homopolar Machines

With the increasing electrification of transportation, the need for high power density electric machines is higher than ever. The required specific power for the more demanding applications, such as airplane propulsion, is over 20 kW/kg for multi-megawatt range power levels. Fully superconducting synchronous machines could reach the required performance, but significant challenges remain to be addressed such as AC losses management and rotating cryogenics implementation. Homopolar machines constitute the simplest electro-mechanical conversion systems possible, however the difficulty of establishing reliable and efficient low voltage, high DC current transfer from a stationary to a rotating system has prevented homopolar machines from competing with AC electrical machines. While sliding contacts or liquid metal contacts are feasible, they lead to high losses, high maintenance requirements and the use of environmentally unfriendly materials. We investigated field emission current transfer as an alternative to sliding contacts. We have demonstrated field emission current transfer in vacuum between a copper electrode and carbon nanotubes and diamond pyramids to evaluate the feasibility of contact-free current transfer for homopolar machines. The initial field emission testing was successfully demonstrated with current densities in the 10 mA/cm 2 range. The initial experiments validated the concept and supported the development of a roadmap for the development of contactless current transfer for homopolar machines, helped understand the limitations of the current test system and identify the key parameters that will lead to better performance.

99 GENERAL AND MISCELLANEOUS↗

Prototype energy models for data centers

Data centers in the United States consume about two percent of the nation’s electricity. Because heat gains from IT equipment drive cooling demand, data centers offer unique opportunities for energy savings. However, no prototype energy model for data centers is available in the suite of existing U.S. Department of Energy’s Commercial Prototype Building Models. Here we present the development of two new data center prototype models and their implementation in OpenStudio and EnergyPlus. The small-size data center model represents a computer room in a building served by computer room air conditioners (CRACs); while the large-sized model represents stand-alone data centers served by computer room air handlers (CRAHs) with a central chiller plant. For each data center model, two levels of IT equipment (ITE) load density were considered, to cover the wide range of IT power density of data centers: 40 and 100 W/ft 2 (430 and 1076 W/m 2 ) for the computer room, and 100 and 500 W/ft 2 (1076 and 5382 W/m 2 ) for the stand-alone data center. All other assumptions, such as building envelope, lighting, HVAC efficiencies and schedules, were based on the minimal requirements of ASHRAE Standard 90.1 at various vintages. We introduced a novel concept of supply and return air approach temperatures to capture the essential effects of non-uniform airflow and temperature distribution in data centers. The approach temperatures were pre-computed by computational fluid dynamics (CFD) simulations for various configurations of ITE loads and airflow containment management in data centers. A new feature was developed in EnergyPlus to implement the approach temperature method. A case study was conducted to demonstrate the use of the data center models. The two data center models cover all U.S. climate zones and can be used to evaluate energy saving measures for data centers, as well as to support development of data center energy efficiency codes and standards.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Electric Drive Technology Trends, Challenges, and Opportunities for Future Electric Vehicles

The transition to electric road transport technologies requires electric traction drive systems to offer improved performances and capabilities, such as fuel efficiency (in terms of MPGe, i.e., miles per gallon of gasoline-equivalent), extended range, and fast-charging options. The enhanced electrification and transformed mobility are translating to a demand for higher power and more efficient electric traction drive systems that lead to better fuel economy for a given battery charge. To accelerate the mass-market adoption of electrified transportation, the U.S. Department of Energy (DOE), in collaboration with the automotive industry, has announced the technical targets for light-duty electric vehicles (EVs) for 2025. This article discusses the electric drive technology trends for passenger electric and hybrid EVs with commercially available solutions in terms of materials, electric machine and inverter designs, maximum speed, component cooling, power density, and performance. Additionally, the emerging materials and technologies for power electronics and electric motors are presented, identifying the challenges and opportunities for even more aggressive designs to meet the need for next-generation EVs. Some innovative drive and motor designs with the potential to meet the DOE 2025 targets are also discussed.

33 ADVANCED PROPULSION SYSTEMS↗

Northstar Mo100 Target Beam Spot Size Sensitivity Study

Northstar Mo100 target for production of the medical isotope Mo99 is particularly sensitive to beam over focusing because of the intended high power density. At 38 MeV and 6.32 mA (240 kW beam power, nominally 160 kW th in the target), small deviation from the nominal 12 mm FWHM beam can significantly increase the target disk temperatures and more importantly the load bearing target window temperature. A rhodotron will be the source of the electron beam to be used in the isotope production. This machine operates in a pulsed beam mode, currently expected to be at 50 Hz, which results in a 100 C temperature oscillation above and below the steady state temperature that is the focus of this study. This must be considered in the determination of minimum beam spot size that can be accepted by the target without risk of failure. In addition to the nominal beam spot size of 12 mm, the analysis of 10, 11 and 14.5 mm beam spot sizes are analyzed. The primary conclusion is that an over focused beam to just 11 mm FWHM is the minimum beam spot allowable, based on window temperature and the Ultimate Tensile Stress (UTS) of the window material Inconel 718 as a function of temperature. In contrast an under focused beam of 14.5 mm FWHM has much reduced target and window temperatures, but there is a resulting 6% drop in isotope production, all other factor staying the same. These results are presented herein.

07 ISOTOPE AND RADIATION SOURCES↗

Development of High Capacity Energy Storage Materials

Hydrogen fuel cells have the potential to offer energy and power density advantages over lithium ion batteries in automotive and portable power applications when paired with an appropriate hydrogen storage system. Development of the ideal hydrogen storage material has been immensely sought after but plagued by limitations present in each type of material. These limitations typically include nonidealistic operational temperatures, low capacities, excessive costs, lack of reversibility, or evolution of impurities which irreversibly damage fuel cell performance. Many complex metal hydrides possess suitable hydrogen capacities but unfortunately suffer from impurity release. In order to address this problem, our team has explored in-situ catalyst doping of alkali metal amides to demonstrate methodologies to reduce ammonia release. The incorporation of iridium metal in lithium amide significantly reduces the ammonia release and decomposes the ammonia to provide additional hydrogen. Furthermore, we demonstrate, for the first time, high resistance of low temperature fuel cells to ammonia in comparison with typical proton exchange membrane fuel cells. The utilization of these two approaches in tandem provides a novel pathway for the development and implementation of high capacity energy storage materials for fuel cell applications.

25 ENERGY STORAGE↗

Effects of land-based wind turbine upsizing on community sound levels and power and energy density

Multiple technological, social, and market factors of wind power are evolving rapidly. Most notably, significant wind turbine scaling is occurring and is forecasted to continue. While the larger turbines expected to be deployed in the future are more powerful and efficient, they are also expected to operate at higher sound levels and require larger setbacks than those installed in the last decade. These sometimes-competing deployment trends and impacts cannot be understood via simple extrapolations of past trends. This study analyzes the effect of these future larger turbines on wind turbine micro-siting, project-level power and energy density, and community noise impacts. Due to their taller heights, larger rotors, and higher sound power levels, future wind turbines will require larger setbacks from homes and greater inter-turbine spacing, resulting in fewer turbines deployed for a given land area. This research finds these changes more than offset the effect of the higher turbine sound emissions, significantly decreasing the average sound levels that wind plant hosting communities experience. Yet, simultaneously, plant layouts using future turbine designs also result in projects with higher installed capacities and annual energy output for a given land area. These increases will likely lead to increased tax benefits and local income in the community. The deployment of fewer turbines on a smaller number of parcels could have implications on siting flexibility and landowner payments.

17 WIND ENERGY↗

Doping-modulated strain control of bifunctional electrocatalysis for rechargeable zinc–air batteries

Changes in the local atomic arrangement in a crystal caused by lattice-mismatch-induced strain can efficiently regulate the performance of electrocatalysts for zinc–air batteries (ZABs) in many manners, mainly due to modulated electronic structure configurations that affect the adsorption energies for oxygen-intermediates formed during oxygen reduction and evolution reactions (ORR and OER). However, the application of strain engineering in electrocatalysis has been limited by the strain relaxation caused by structural instability such as dissolution and destruction, leading to insufficient durability towards the ORR/OER. In this work, we propose a doping strategy to modulate the phase transition and formation of self-supported cobalt fluoride–sulfide (CoFS) nanoporous films using a low amount of copper (Cu) as a dopant. This well-defined Cu–CoFS heterostructure overcomes the obstacle of structural instability. Our study of the proposed Cu–CoFS also helps establish the structure–property relationship of strained electrocatalysts by unraveling the role of local strain in regulating the electronic structure of the catalyst. As a proof-of-concept, the Cu–CoFS electrocatalyst with doping-modulated strain exhibited superior onset potentials of 0.91 V and 1.49 V for the ORR and OER, respectively, surpassing commercial Pt/C@RuO 2 and benchmarking non-platinum group metal (non-PGM) catalysts. ZABs with the Cu–CoFS catalyst delivered excellent charge/discharge cycling performance with an extremely low voltage gap of 0.5 V at a current density of 10 mA cm –2 and successively 0.93 V at a high current density of 100 mA cm –2 and afforded an outstanding peak power density of 255 mW cm –2 .

25 ENERGY STORAGE↗

Shield Design for 50 kW Three-Phase Wireless Charging System

In this paper, magnetic field emissions (MFE) from a 50 kW bipolar coil-based three-phase wireless charging system (WCS) is investigated. Then, a shield design is proposed to suppress the MFE below the safety limit identified by the International Commission of Non-Ionized Radiation Protection (ICNIRP) guidelines. Bipolar coil-based three-phase (3φ) WCSs provide extremely high power-density; therefore, the 3φ WCSs are highly promising for high-power fast-wireless-charging of the electric vehicles. For the high-power EV application, it is a critical challenge to design a shield to suppress the MFE below the safety limit. The traditional aluminum shield is found ineffective for the bipolar 3φ-WCS. The proposed shield is designed with high-permeability magnetic material, i.e. ferrite, nanocrystalline material, etc. The proposed shield is simulated in finite element analysis (FEA) and the FEA results show that the proposed magnetic shield effectively suppresses the magnetic field emission below the ICNIRP limit. The generalized design of the proposed shield can be used for even higher power bipolar coil based WCSs.

Mohammad, Mostak↗