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At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

High-Efficiency Recycled Silicon Solar Cell

The project, High-Efficiency Recycled Silicon Solar Cell, addresses the critical challenge of end-of-life (EoL) photovoltaic (PV) waste, which is expected to reach 78 million tons by 2050. Traditional recycling methods for recovering valuable materials like silver from silicon solar cells are inefficient, environmentally harmful, and economically unfeasible. Therefore, presently waste solar cells end up as landfills. This project aimed to develop a green, scalable, laser-based method for silver recovery, avoiding hazardous chemicals and minimizing operational costs. This research contributes to the circular economy in the renewable energy sector by enhancing material recovery from PV waste.

14 SOLAR ENERGY↗
DOE OSTI2026

Towards Commercialization of Low-Cost, Crack-Tolerant, Screen-Printable Metallization by Full-Size Module Testing and Field Characterization

This project is motivated by the need to develop a materials engineering solution to reduce solar module degradation caused by cell cracks. The cell-crack-induced power loss is a long-term degradation mechanism and one of the main causes of solar panel field failures. Cell cracks can occur during module fabrication, transportation, installation, and long-term operation due to thermomechanical stressors. Our team’s internal estimation – based on the national weather pattern, frequency of severe weather, and 39- GW asset survey by Heliolytics – reveals that the cell-crack-induced module degradation translates to lost revenues >$17B over an average 5-year period for solar farm owners and to reduced reliability (<25 years panel lifetime) for solar energy consumers. In response to this challenge, the prime recipient offers a metal matrix composite (MMC) silver paste that is tailor-engineered for screen-printing gridlines and busbars, which serve as the electrical contacts on solar cells. We formulate our MMC paste by adding low-cost (∼0.02¢/WDC for research grade), surface-engineered carbon nanotubes to commercially available silver paste. The MMC paste offers a drop-in, cost-effective solution to cell cracks for solar cell and module manufacturers. The main goal of this project was to conduct field-relevant, module-level analysis and qualification of MMC metallization.

14 SOLAR ENERGY↗
DOE OSTI2025

Structure of Odd-A Ag Isotopes Studied via Algebraic Approaches

The structure of the odd-A silver isotopes Ag 103–115 is discussed within the frame of the interacting boson–fermion model (IBFM). An overview of their key properties is presented, with a particular attention paid to the “ J -1 anomaly”, represented by an abnormal ordering of the lowest 7/2 + and 9/2 + states. By examining previously published data and newly performed calculations, it is demonstrated that the experimentally known level schemes and electromagnetic properties of Ag 103–115 can be reproduced well within IBFM-1 by using a consistent set of model parameters. The contribution of different single-particle orbitals to the structure of the lowest-lying excited nuclear states in Ag 103–115 is discussed. Given that the J-1 anomaly brings down the 7/2 + level from the j −3 multiplet to energies, which can be thermally populated in hot stellar environments, the importance of low-lying excited states in odd-A silver isotopes for astrophysical processes is outlined.

IBFM-1↗
DOE OSTI2020

Coproduction of Light and Heavy r-process Elements via Fission Deposition

We apply for the first time fission yields determined across the chart of nuclides from the macroscopic-microscopic theory of the Finite Range Liquid Drop Model to simulations of rapid neutron capture (r-process) nucleosynthesis. With the fission rates and yields derived within the same theoretical framework utilized for other relevant nuclear data, our results represent an important step toward self-consistent applications of macroscopic-microscopic models in r-process calculations. The yields from this model are wide for nuclei with extreme neutron excess. We show that these wide distributions of neutron-rich nuclei, and particularly the asymmetric yields for key species that fission at late times in the r process, can contribute significantly to the abundances of the lighter heavy elements, specifically the light precious metals palladium and silver. Since these asymmetric yields correspondingly also deposit into the lanthanide region, we consider the possible evidence for coproduction by comparing our nucleosynthesis results directly with the trends in the elemental ratios of metal-poor stars rich in r-process material. We show that for r-process enhanced stars palladium over europium and silver over europium display mostly flat trends suggestive of coproduction and compare to the lanthanum over europium trend which is often used to justify robustness arguments in the lanthanide region. We find that such robustness arguments may be extendable down to palladium and heavier and demonstrate that fission deposition is a mechanism by which such a universality or robustness can be achieved.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Closing the Loops on Solar Photovoltaics Modules: An Agent-Based Modeling Approach for the Study of Circular Economy Strategies

Solar photovoltaics (PV) installed capacity have grown exponentially since the early 2000s (average annual growth rate of 50%). With 4,700 GW projected installed capacity by 2050, the volume of PV panels waste is also expected to become substantial. Though renewables are a sine qua non to the establishment of a truly circular economy (CE), the issue arising from their end-of-life management needs to be resolved. The management of PV end-of-life also represent a singular opportunity to create value, from recovered valuable, rare or critical materials (e.g. silver, tellurium, indium). Moreover, the PV case illustrates some of the current barriers to CE; for instance, the need for a common definition of waste (PV are defined as e-waste in the European Union but as general waste in the United States) and potential loss of innovations' advantages (PV average efficiency has continuously grown the past 10 years). In this study, an agent-based modeling (ABM) approach is proposed to simulate PV end-of-life management in the United States. The model explores how the decisions of the various actors involved in handling PV waste affect the quantities of PV that are reused, recycled, or land-filled. In the model, manufacturers, residential, and nonresidential PV owners, installers, and recyclers are represented by agents while governmental policies and regulations are treated as exogenous variables. PV-market data are used to define agents' characteristics (e.g., installed PV capacities or producing costs). Agents' decision rules draw on the literature related to industrial symbiosis (IS) and peoples' waste behaviors as they appear as the most widely used model to implement CE principles at a meso level. Specifically, the concepts of mutual trust between IS actors and knowledge about the IS philosophy are yielded to define the agents' decision process. The primary outputs of the ABM are the costs and volume of waste associated with each end-of-life pathway. Preliminaries results indicate recycling of residential PV is affected by the cost, perceived difficulty of recycling behaviors, and social norms. Moreover, the type of network connecting agents and the initial recycling rate strongly influence results. The model also highlights the crucial role of recycling behavior adoption: in case of early failure of PV, recycled volumes increase by about 40%. This represents an additional 5.7 billion USD from potential recovered silver. Finally, although results for the PV case are presented here, the developed ABM aims at being a general tool for the study of CE strategies and the CE transition. Furthermore, steps of this research include extending the model to encompass circular economy strategies (e.g., design for recycling or lifetime extension) and validating its general architecture from various case studies.

14 SOLAR ENERGY↗
DOE OSTI2020

Comparison of Fission Product Release Predictions using PARFUME with Results from the AGR-2 Irradiation Experiment

The PARFUME (PARticle FUel ModEl) code was used to predict fission product release from tristructural isotropic (TRISO) coated fuel particles and compacts during the second irradiation experiment (AGR-2) of the Advanced Gas Reactor Fuel Development and Qualification Program. The PARFUME model for the Advanced Gas reactor (AGR)GR-2 experiment used the fuel compact volume average temperature for each of the 560 days of irradiation to calculate the release of fission products of silver, cesium, and strontium from a representative particle for a select number of AGR -2 compacts. In addition, safety tests were performed on 15 compacts ranging from 1500 to 1800°C to determine fission product release at temperatures that bound reactor accident conditions. PARFUME was used to calculate the fission product release of silver, cesium, strontium, and krypton during these safety tests. Post-irradiation examination (PIE) measurements provided the data on release of fission products from the fuel compacts and fuel particles, and retention of fission products in the compacts outside the silicon carbide (SiC) layer. The predicted fraction release from PARFUME was then compared to PIE measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Investigation of Local Parameters of PERC Solar Cells Metallized with Screen Printed Cu-Paste

For 40 TW of PV required to transition our planet to 100% renewables, the silver (Ag) should disappear from PV production. Advantages of copper (Cu) over silver (Ag) include: 1) bulk Cu has a similar conductivity to Ag (1.7 one millionth O-cm for Cu, 1.6 one millionth O-cm for Ag, and 2) Cu is -100 times cheaper than Ag, making it an excellent potential replacement. Problems associated with copper contacts include: 1) easy oxidation, and 2) diffusion into the Si cell and recombination activity. To summarize: 1) Rs map shows some regions with very high Rs, indicating no contact in those areas; 2) the histogram shows the peak Rs -5 ohm.cm2, which explains the high FF loss due to Rs; and 3) DLIT indicates non-uniformity in J01 and J02.

copper↗
DOE OSTI2024

Exploring the Performance and Reliability of Screen-Printable Fire-Through Copper Paste on PERC Solar Cells

For 40 TW of PV required to transition our planet to 100% renewables, the silver (Ag) should disappear from PV production. Advantages of copper (Cu) over silver (Ag) include 1) bulk Cu has a similar conductivity to Ag (1.7 mu O-cm for Cu, 1.6 mu O-cm for Ag) and 2) Cu is approximately 100 times cheaper than Ag, making it an excellent potential replacement. Problems associated with copper (Cu) contacts include 1) easy oxidation and 2) diffusion into the Si cell and recombination activity.

copper paste↗
DOE OSTI2024

Post-irradiation Heating Tests of As-Irradiated AGR-3/4 TRISO Fuel Compacts

Four post-irradiation heating tests of fuel compacts from the U.S. Advanced Gas Reactor (AGR)-3/4 irradiation experiment were completed. In addition to tristructural isotropic (TRISO)-coated driver fuel, each compact contained designed-to-fail (DTF) particles with fuel kernels coated only in pyrocarbon so as to simulate exposed kernels. Tests at 1600/1700°C, 1400°C, and 1200°C were performed to measure fission product release as a function of time and temperature. Silver release was highest in the 1200°C test, supporting the observation that silver release rates are highest in the 1100–1300°C range. Compared to tests of AGR-1 compacts with no exposed kernels, the Cs-134 and Kr-85 releases were noticeably higher in AGR-3/4. The exposed kernels’ contributions to Eu and Sr release are inconclusive, due to the difficulty in distinguishing among the combined effects of higher irradiation temperatures in these particular AGR-3/4 compacts, the presence of the DTF particles, and the Fuel Accident Condition Simulator (FACS) test temperatures. These data can be used to make inferences about fission product retention in exposed kernels as a function of time and temperature.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

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↗
DOE OSTI2020

Pd3Ag(111) as a Model System for Hydrogen Separation Membranes: Combined Effects of CO Adsorption and Surface Termination on the Activation of Molecular Hydrogen

Abstract The co-adsorption of hydrogen and carbon monoxide on Pd 3 Ag(111) alloy surfaces has been studied as a model system for Pd-Ag alloys in membrane and catalysis applications using periodic density functional theory calculations (PW91-GGA). We explored the effects of Pd–Ag surface composition, since segregation of silver towards and away from the surface has been suggested to explain the experimentally observed changes in H 2 activation, CO inhibition and reactivity. We found that CO pre-adsorbed on the surface weakens the adsorption of H on Pd 3 Ag(111) alloy surfaces irrespective of whether the surface termination corresponds to the bulk Pd 3 Ag composition, or is purely Pd-terminated. A higher coverage of H with CO present is obtained for the Pd-terminated surface; this surface also exhibits a larger range of chemical potentials for co-adsorbed hydrogen and CO. The barrier for H 2 activation increases with increasing CO coverage, but the surface composition has the largest impact on H 2 activation at intermediate CO coverage. The results imply that Pd-based membranes with typically ~ 23 wt% Ag are less prone to CO poisoning if the surface becomes Pd-terminated.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

The Influence of Microstructure on TCR for Inkjet-Printed Resistive Temperature Detectors Fabricated Using AgNO 3 /Ethylene-Glycol-Based Inks

This study investigated the influence of microstructure on the performance of Ag inkjet-printed, resistive temperature detectors (RTDs) fabricated using particle-free inks based on a silver nitrate (AgNO 3 ) precursor and ethylene glycol as the ink solvent. Specifically, the temperature coefficient of resistance (TCR) and sensitivity for sensors printed using inks that use monoethylene glycol (mono-EG), diethylene glycol (di-EG), and triethylene glycol (tri-EG) and subjected to a low-pressure argon (Ar) plasma after printing were investigated. Scanning electron microscopy (SEM) confirmed previous findings that microstructure is strongly influenced by the ink solvent, with mono-EG inks producing dense structures, while di- and tri-EG inks produce porous structures, with tri-EG inks yielding the most porous structures. RTD testing revealed that sensors printed using mono-EG ink exhibited the highest TCR (1.7 × 10 -3 /°C), followed by di-EG ink (8.2 × 10 -4 /°C) and tri-EG ink (7.2 × 10 -4 /°C). These findings indicate that porosity exhibits a strong negative influence on TCR. Sensitivity was not strongly influenced by microstructure but rather by the resistance of RTD. The highest sensitivity (0.84 Ω/°C) was observed for an RTD printed using mono-EG ink but not under plasma exposure conditions that yield the highest TCR.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Mesoporous PdAg Nanospheres for Stable Electrochemical CO 2 Reduction to Formate

Palladium is a promising material for electrochemical CO 2 reduction to formate with high Faradaic efficiency near the equilibrium potential. It unfortunately suffers from problematic operation stability due to CO poisoning on surface. In this work, it is demonstrated that alloying is an effective strategy to alleviate this problem. Mesoporous PdAg nanospheres with uniform size and composition are prepared from the co-reduction of palladium and silver precursors in aqueous solution using dioctadecyldimethylammonium chloride as the structure-directing agent. The best candidate can initiate CO 2 reduction at zero overpotential and achieve high formate selectivity close to 100% and great stability even at <-0.2 V versus reversible hydrogen electrode. The high selectivity and stability are believed to result from the electronic coupling between Pd and Ag, which lowers the d-band center of Pd and thereby significantly enhances its CO tolerance, as evidenced by both electrochemical analysis and theoretical simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bulk Layering Effects of Ag and Cu for Tandem CO 2 Electrolysis

The electrochemical reduction of carbon dioxide (CO 2 ) presents an opportunity to close the carbon cycle and obtain sustainably sourced carbon compounds. In recent years, copper has received widespread attention as the only catalyst capable of meaningfully producing multi-carbon (C 2+ ) species. Notably carbon monoxide (CO) can also be reduced to C 2+ compounds on copper, motivating tandem systems that combine copper and CO-producing species, like silver, to enhance overall C 2+ selectivities. In this work, we examine the impact of layered-combinations of bulk Cu and Ag by varying the location and proportion of the CO-producing Ag layer. We report an effective increase in the C 2+ oxygenate selectivity from 23 % with a 100 nm Cu to 38 % for a 100: 15 nm Cu : Ag layer. Notably, however, for all co-catalyst cases there is an overproduction of CO vs Cu alone, even for 5 nm Ag layers. Lastly, due to restructuring and interlayer mobility of the copper layer it is clear that the stability of copper limits the locational advantages of such tandem solutions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Dual-atom Ag 2 /graphene catalyst for efficient electroreduction of CO 2 to CO

Electrochemical reduction of CO 2 into value-added carbon compounds offers a promising strategy to mitigate global warming, but present challenges for chemistry due to the poor selectivity and stability of electrocatalysts. In this work, we report a dual-atom Ag 2 /graphene catalyst featuring well-defined AgN 3 -AgN 3 active site for CO 2 electrochemical reduction. This dual-atom catalyst can drive CO 2 reduction reaction at a potential as high as -0.25 V, and exhibit excellent CO Faradic efficiency up to 93.4 % with a current density of 11.87 mA cm -2 at -0.7 V and long-term stability, far surpassing the single-atom Ag 1 /graphene and the traditional silver nanoparticle catalysts. Finally, DFT calculations reveal that the dual-atom Ag site lowers the barrier for the formation of *COOH by stabilizing the *CO 2 through the concomitant interactions with the C and an O atom of CO 2 , resulting in excellent catalytic performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Effect of grafting density on the two-dimensional assembly of nanoparticles

Employing grazing-incidence small-angle X-ray scattering (GISAXS) and X-ray reflectivity (XRR), we demonstrate that films composed of polyethylene glycol (PEG)-grafted silver nanoparticles (AgNPs) and gold nanoparticles (AuNPs), as well as their binary mixtures, form highly stable hexagonal structures at the vapor–liquid interface. These nanoparticles exhibit remarkable stability under varying environmental conditions, including changes in pH, mixing concentration, and PEG chain length. Short-chain PEG grafting produces dense, well-ordered films, while longer chains produce more complex, less dense quasi-bilayer structures. AuNPs exhibit higher grafting densities than AgNPs, leading to more ordered in-plane arrangements. In binary mixtures, AuNPs dominate the population at the surface, while AgNPs integrate into the system, expanding the lattice without forming a distinct binary superstructure. In conclusion, these results offer valuable insights into the structural behavior of PEG-grafted nanoparticles and provide a foundation for optimizing binary nanoparticle assemblies for advanced nanotechnology applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Synthesis of N-trifluoromethyl amides from carboxylic acids

Found in biomolecules, pharmaceuticals, and agrochemicals, amide-containing molecules are ubiquitous in nature, and their derivatization represents a significant methodological goal in fluorine chemistry. Trifluoromethyl amides have emerged as important functional groups frequently found in pharmaceutical compounds. To date, there is no strategy for synthesizing N -trifluoromethyl amides from abundant organic carboxylic acid derivatives, which are ideal starting materials in amide synthesis. Here, we report the synthesis of N -trifluoromethyl amides from carboxylic acid halides and esters under mild conditions via isothiocyanates in the presence of silver fluoride at room temperature. Through this strategy, isothiocyanates are desulfurized with AgF, and then the formed derivative is acylated to afford N -trifluoromethyl amides, including previously inaccessible structures. This method shows broad scope, provides a platform for rapidly generating N -trifluoromethyl amides by virtue of the diversity and availability of both reaction partners, and should find application in the modification of advanced intermediates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗