Applications for a New Scalable, Low Weight, High Power Density Nuclear Battery and Thermal Electrics
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Dennis M. Bushnell↗
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Hybrid Power Management-Based Vehicle Architecture
Hybrid Power Management (HPM) is the integration of diverse, state-of-the-art power devices in an optimal configuration for space and terrestrial applications (s ee figure). The appropriate application and control of the various power devices significantly improves overall system performance and efficiency. The basic vehicle architecture consists of a primary power source, and possibly other power sources, that provides all power to a common energy storage system that is used to power the drive motors and vehicle accessory systems. This architecture also provides power as an emergency power system. Each component is independent, permitting it to be optimized for its intended purpose. The key element of HPM is the energy storage system. All generated power is sent to the energy storage system, and all loads derive their power from that system. This can significantly reduce the power requirement of the primary power source, while increasing the vehicle reliability. Ultracapacitors are ideal for an HPM-based energy storage system due to their exceptionally long cycle life, high reliability, high efficiency, high power density, and excellent low-temperature performance. Multiple power sources and multiple loads are easily incorporated into an HPM-based vehicle. A gas turbine is a good primary power source because of its high efficiency, high power density, long life, high reliability, and ability to operate on a wide range of fuels. An HPM controller maintains optimal control over each vehicle component. This flexible operating system can be applied to all vehicles to considerably improve vehicle efficiency, reliability, safety, security, and performance. The HPM-based vehicle architecture has many advantages over conventional vehicle architectures. Ultracapacitors have a much longer cycle life than batteries, which greatly improves system reliability, reduces life-of-system costs, and reduces environmental impact as ultracapacitors will probably never need to be replaced and disposed of. The environmentally safe ultracapacitor components reduce disposal concerns, and their recyclable nature reduces the environmental impact. High ultracapacitor power density provides high power during surges, and the ability to absorb high power during recharging. Ultracapacitors are extremely efficient in capturing recharging energy, are rugged, reliable, maintenance-free, have excellent lowtemperature characteristic, provide consistent performance over time, and promote safety as they can be left indefinitely in a safe, discharged state whereas batteries cannot.
Eichenberg, Dennis J.↗
SiC Multi-Chip Power Modules as Power-System Building Blocks
The term "SiC MCPMs" (wherein "MCPM" signifies "multi-chip power module") denotes electronic power-supply modules containing multiple silicon carbide power devices and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking. Moreover, the higher-temperature capabilities of SiC MCPMs could enable operation in environments hotter than Si-based power systems can withstand. The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules. In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications: typical functions could include regulating voltages, storing energy, and driving motors. Because identical SiC MCPM building blocks could be utilized in a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. Several prototype DC-to-DC power-converter modules containing SiC power-switching devices were designed and built to demonstrate the feasibility of the SiC MCPM concept. In anticipation of a future need for operation at high temperature, the circuitry in the modules includes high-temperature inductors and capacitors. These modules were designed to be stacked to construct a system of four modules electrically connected in series and/or parallel. The packaging of the modules is designed to satisfy requirements for series and parallel interconnection among modules, high power density, high thermal efficiency, small size, and light weight. Each module includes four output power connectors two for serial and two for parallel output power connections among the modules. Each module also includes two signal connectors, electrically isolated from the power connectors, that afford four zones for signal interconnections among the SOI controllers. Finally, each module includes two input power connectors, through which it receives power from an in-line power bus. This design feature is included in anticipation of a custom-designed power bus incorporating sockets compatible with snap-on type connectors to enable rapid replacement of failed modules.
Lostetter, Alexander↗
NASA work on high-energy-density electrochemical power devices
Electrochemical research and development - high energy and high power density devices for spacecraft applications
Cohn, E. M.↗
Cooling of Electric Motors Used for Propulsion on SCEPTOR
Benefits of Electric Power: Reduced energy consumption, Lower emissions, Less noise. Traction motors: Permanent magnet, Synchronous, High torque at low rotational speeds, High power density, (High concentration of heat). Annular inlet: Very compatible with PM motors, (Provides cooling where needed, No need for complicated ducting, Leads to a larger motor diameter which is beneficial for motor torque) Effect of prop wash on heat transfer coefficients: Assumed propeller induced turbulence would increase heat transfer coefficients, Holmes, Obara Yip reported 'propeller slipstream showed little if any apparent effect of the slip stream', Derlaga @ LaRC also found little change in heat transfer in the wake of the propeller.
Aircraft↗
Motor/Generator and Inverter Characterization for Flywheel System Applications
The Advanced Electrical Systems Development Branch at NASA Glenn Research Center (GRC) has been involved in the research and development of high speed flywheels systems for satellite energy storage and attitude applications. These flywheels will serve as replacement for chemical nickel hydrogen, nickel cadmium batteries and gyroscopic wheels. The advantages of using flywheel systems for energy storage on satellites are high energy density, high power density, long life, deep depth of discharge, and broad operating temperature ranges. A flywheel system for space applications consist of a number of flywheel modules, the motor/generator and magnetic bearing, and an electronics package. The motor/generator electronics package includes a pulse-width modulated inverter that drives the flywheel permanent magnet motor/generator located at one end of the shaft. This summer, I worked under the direct supervision of my mentor, Walter Santiago, and the goal for this summer was to characterize motor generator and inverter attributes in order to increase their viability as a more efficient energy storage source for space applications. To achieve this goal, magnetic field measurements around the motor/generator permanent magnet and the impedance of the motor/generator three phase windings were characterized, and a recreation of the inverter pulse width modulated control system was constructed. The Flywheel modules for space use are designed to maximize energy density and minimize loss, and attaining these values will aid in locating and reducing losses within the flywheel system as a whole, making flywheel technology more attractive for use as energy storage in future space applications.
Tamarcus, Jeffries L.↗
Nano-Magnets and Additive Manufacturing for Electric Motors
High power density is required for application of electric motors in hybrid electric propulsion. Potential path to achieve high power density in electric motors include advanced materials, lightweight thermal management, lightweight structural concepts, high power density power electronics, and advanced manufacturing. This presentation will focus on two key technologies for achieving high power density, advanced magnets and additive manufacturing. The maximum energy product in current magnets is reaching their theoretical limits as a result of material and process improvements. Future improvements in the maximum energy product for magnets can be achieved through development of nanocomposite magnets combining the hard magnetic phase and soft magnetic phase at the nanoscale level. The presentation will provide an overview of the current state of development for nanocomposite magnets and the future path for doubling the maximum energy product. The other part of the presentation will focus on the role of additive manufacturing in fabrication of high power density electric motors. The presentation will highlight the potential opportunities for applying additive manufacturing to fabricate electric motors.
materials↗
The Vasimr Engine: Project Status and Recent Accomplishments
The development of the Variable Specific Impulse Magnetoplasma Rocket (VASIMR) was initiated in the late 1970s to address a critical requirement for fast, high-power interplanetary space transportation. While not being a fusion rocket, it nevertheless borrows heavily from that technology and takes advantage of the natural topology of open-ended magnetic systems. In addition to its high power density and high exhaust velocity, VASIMR is capable of "constant power throttling" a feature, which allows in-flight mission-optimization of thrust and specific impulse to enhance performance and reduce trip time. A NASA-led, research team, involving industry, academia and government facilities is pursuing the development of this concept in the United States. The technology can be validated, in the near term, in venues such as the International Space Station, where it can also serve as both a drag compensation device and a plasma contactor for the orbital facility. Other near-Earth applications in the commercial and scientific satellite sectors are also envisioned. This presentation covers the evolution of the VASIMR concept to its present status, as well as recent accomplishments in our understanding of the physics. Approaches and collaborative programs addressing the major technical challenges will also be presented.
ChangDiaz, Franklin R.↗
High thermal power density heat transfer apparatus providing electrical isolation at high temperature using heat pipes
This invention is directed to transferring heat from an extremely high temperature source to an electrically isolated lower temperature receiver. The invention is particularly concerned with supplying thermal power to a thermionic converter from a nuclear reactor with electric isolation. Heat from a high temperature heat pipe is transferred through a vacuum or a gap filled with electrically nonconducting gas to a cooler heat pipe. If the receiver requires gratr thermal power density, geometries are used with larger heat pipe areas for transmitting and receiving energy than the area for conducting the heat to the thermionic converter. In this way the heat pipe capability for increasing thermal power densities compensates for the comparative low thermal power densities through the electrically nonconducting gap between the two heat pipes.
Morris, J. F.↗
Fuel Cells for Space Science Applications
Fuel cell technology has been receiving more attention recently as a possible alternative to the internal combustion engine for our automobile. Improvements in fuel cell designs as well as improvements in lightweight high-pressure gas storage tank technology make fuel cell technology worth a look to see if fuel cells can play a more expanded role in space missions. This study looks at the specific weight density and specific volume density of potential fuel cell systems as an alternative to primary and secondary batteries that have traditionally been used for space missions. This preliminary study indicates that fuel cell systems have the potential for energy densities of greater than 500 W-hr/kg, greater than 500W/kg and greater than 400 W-hr/liter, greater than 200 W/liter. This level of performance makes fuel cells attractive as high-power density, high-energy density sources for space science probes, planetary rovers and other payloads. The power requirements for these space missions are, in general, much lower than the power levels where fuel cells have been used in the past. Adaptation of fuel cells for space science missions will require down-sizing the fuel cell stack and making the fuel cell operate without significant amounts of ancillary equipment.
Burke, Kenneth A.↗
Recent advances in solid polymer electrolyte fuel cell technology with low platinum loading electrodes
Of all the fuel cell systems only alkaline and solid polymer electrolyte fuel cells are capable of achieving high power densities (greater than 1 W/sq cm) required for terrestrial and extraterrestrial applications. Electrode kinetic criteria for attaining such high power densities are discussed. Attainment of high power densities in solid polymer electrolyte fuel cells has been demonstrated earlier by different groups using high platinum loading electrodes (4 mg/sq cm). Recent works at Los Alamos National Laboratory and at Texas A and M University (TAMU) demonstrated similar performance for solid polymer electrolyte fuel cells with ten times lower platinum loading (0.45 mg/sq cm) in the electrodes. Some of the results obtained are discussed in terms of the effects of type and thickness of membrane and of the methods platinum localization in the electrodes on the performance of a single cell.
Srinivasan, Supramaniam↗
High thermal power density heat transfer
Heat from a high temperature heat pipe is transferred through a vacuum or a gap filled with electrically nonconducting gas to a cooler heat pipe. The heat pipe is used to cool the nuclear reactor while the heat pipe is connected thermally and electrically to a thermionic converter. If the receiver requires greater thermal power density, geometries are used with larger heat pipe areas for transmitting and receiving energy than the area for conducting the heat to the thermionic converter. In this way the heat pipe capability for increasing thermal power densities compensates for the comparatively low thermal power densities through the electrically non-conducting gap between the two heat pipes.
Morris, J. F.↗
Recent advances in solid polymer electrolyte fuel cell technology with low platinum loading electrodes
High power density fuel cell systems for defense and civilian applications are being developed. Taking into consideration the main causes for efficiency losses (activation, mass transport and ohmic overpotentials) the only fuel cell systems capable of achieving high power densities are the ones with alkaline and solid polymer electrolyte. High power densities (0.8 W/sq cm at 0.8 V and 1 A/sq cm with H2 and O2 as reactants), were already used in NASA's Apollo and Space Shuttle flights as auxiliary power sources. Even higher power densities (4 W/sq cm - i.e., 8 A sq cm at 0.5 V) were reported by the USAF/International Fuel Cells in advanced versions of the alkaline system. High power densities (approximately 1 watt/sq cm) in solid polymer electrolyte fuel cells with ten times lower platinum loading in the electrodes (i.e., 0.4 mg/sq cm) were attained. It is now possible to reach a cell potential of 0.620 V at a current density of 2 A/sq cm and at a temperature of 95 C and pressure of 4/5 atm with H2/O2 as reactants. The slope of the linear region of the potential-current density plot for this case is 0.15 ohm-sq cm. With H2/air as reactants and under the same operating conditions, mass transport limitations are encountered at current densities above 1.4 A/sq cm. Thus, the cell potential at 1 A/sq cm with H2/air as reactants is less than that with H2/O2 as reactants by 40 mV, which is the expected value based on electrode kinetics of the oxygen reduction reaction, and at 2 A/sq cm with H2/air as reactant is less than the corresponding value with H2/O2 as reactants by 250 mV, which is due to the considerably greater mass transport limitations in the former case.
Srinivasan, Supramaniam↗
High/variable mixture ratio O2/H2 engine
Vehicle/engine analysis studies have identified the High/Dual Mixture Ratio O2/H2 Engine cycle as a leading candidate for an advanced Single Stage to Orbit (SSTO) propulsion system. This cycle is designed to allow operation at a higher than normal O/F ratio of 12 during liftoff and then transition to a more optimum O/F ratio of 6 at altitude. While operation at high mixture ratios lowers specific impulse, the resultant high propellant bulk density and high power density combine to minimize the influence of atmospheric drag and low altitude gravitational forces. Transition to a lower mixture ratio at altitude then provides improved specific impulse relative to a single mixture ratio engine that must select a mixture ratio that is balanced for both low and high altitude operation. This combination of increased altitude specific impulse and high propellant bulk density more than offsets the compromised low altitude performance and results in an overall mission benefit. Two areas of technical concern relative to the execution of this dual mixture ratio cycle concept are addressed. First, actions required to transition from high to low mixture ratio are examined, including an assessment of the main chamber environment as the main chamber mixture ratio passes through stoichiometric. Secondly, two approaches to meet a requirement for high turbine power at high mixture ratio condition are examined. One approach uses high turbine temperature to produce the power and requires cooled turbines. The other approach incorporates an oxidizer-rich preburner to increase turbine work capability via increased turbine mass flow.
Adams, A.↗
Update on Development of SiC Multi-Chip Power Modules
Progress has been made in a continuing effort to develop multi-chip power modules (SiC MCPMs). This effort at an earlier stage was reported in 'SiC Multi-Chip Power Modules as Power-System Building Blocks' (LEW-18008-1), NASA Tech Briefs, Vol. 31, No. 2 (February 2007), page 28. The following recapitulation of information from the cited prior article is prerequisite to a meaningful summary of the progress made since then: 1) SiC MCPMs are, more specifically, electronic power-supply modules containing multiple silicon carbide power integrated-circuit chips and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking; 2) The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules; and, 3) In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications. Because identical SiC MCPM building blocks could be utilized in such a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. This concludes the information from the cited prior article. The main activity since the previously reported stage of development was the design, fabrication, and testing a 120- VDC-to-28-VDC modular power-converter system composed of eight SiC MCPMs in a 4 (parallel)-by-2 (series) matrix configuration, with normally-off controllable power switches. The SiC MCPM power modules include closed-loop control subsystems and are capable of operating at high power density or high temperature. The system was tested under various configurations, load conditions, load-transient conditions, and failure-recovery conditions. Planned future work includes refinement of the demonstrated modular system concept and development of a new converter hardware topology that would enable sharing of currents without the need for communication among modules. Toward these ends, it is also planned to develop a new converter control algorithm that would provide for improved sharing of current and power under all conditions, and to implement advanced packaging concepts that would enable operation at higher power density.
Lostetter, Alexander↗
NASA Glenn Electric Propulsion Work
NASA Glenn Electrified Aircraft Propulsion (EAP) Presentation Outline: High-Voltage, High-Power EAP - Standards and Regulations - Safety and Certification - High Power Density, High-Efficiency Electric Machines and Drives - Thermal Management - Fault Management - Superconducting Electric Machines - Materials Research - Modeling Tools - Advanced Controls
Electric Propulsion↗
Preparation and Evaluation of Multi-Layer Anodes of Solid Oxide Fuel Cell
The development of an energy device with abundant energy generation, ultra-high specific power density, high stability and long life is critical for enabling longer missions and for reducing mission costs. Of all different types of fuel cells, the solid oxide fuel cells (SOFC) is a promising high temperature device that can generate electricity as a byproduct of a chemical reaction in a clean way and produce high quality heat that can be used for other purposes. For aerospace applications, a power-to-weight of (is) greater than 1.0 kW/kg is required. NASA has a patented fuel cell technology under development, capable of achieving the 1.0 kW/kg figure of merit. The first step toward achieving these goals is increasing anode durability. The catalyst plays an important role in the fuel cells for power generation, stability, efficiency and long life. Not only the anode composition, but its preparation and reduction are key to achieving better cell performance. In this research, multi-layer anodes were prepared varying the chemistry of each layer to optimize the performance of the cells. Microstructure analyses were done to the new anodes before and after fuel cell operation. The cells' durability and performance were evaluated in 200 hrs life tests in hydrogen at 850 C. The chemistry of the standard nickel anode was modified successfully reducing the anode degradation from 40% to 8.4% in 1000 hrs and retaining its microstructure.
Santiago, Diana↗
Ka-Band GaAs FET Monolithic Power Amplifier Development
Over the course of this program, very extensive progress was made in Ka-band GaAs technology. At the beginning of the program, odd-shaped VPE MESFET wafers were used. A breakthrough in power and efficiency was achieved with highly doped (8 x 10(exp 17) cm(exp -3) MBE grown MESFET material. We obtained power of 112 mW with 16 dB gain and 21.6% efficiency at 34 GHz with a monolithic 50-100-250 micron amplifier. The next breakthrough came with the use of heterostructures grown by MBE (AlGaAs/InGaAs where the InGaAs is highly doped). This allowed us to achieve high power density with high efficiency. A benchmark 40% efficiency was achieved with a single-stage 100 micron MMIC at 32.5 GHz. The corresponding three-stage 50-100-250 micron amplifier achieved 180 mW with 23 dB gain and 30.3% efficiency. The next breakthrough came with 3-inch MBE grown PHEMT wafers incorporating an etch-stop layer for the gate recess (using RIE). Again, state-of-the-art performances were achieved: 40% efficiency with 235 mW output power and 20.7 dB gain. The single-stage 2 x 600 micron chip demonstrated 794 mW output power with 5 dB gain and 38.2% power-added efficiency (PAE). The Ka-band technology developed under this program has promise for extensive use: JPL demonstrated 32 GHz phased arrays with a three-stage amplifier developed under this contract. A variation of the three-stage amplifier was used successfully in a 4 x 4 phased array transmitter developed under another NASA contract.
Saunier, Paul↗