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DOE OSTI2023

Power Electronics Thermal Management

The 2017 Electrical and Electronics Technical Team Roadmap [1] proposes aggressive research and development targets aimed at improving power electronics technology to enable the mass-market penetration of electric-drive vehicles. Achieving these aggressive targets will require a decrease in cost (year 2025 cost target: $2.70/kW) and an increase in power density (year 2025 power density target: 100 kW/L) as compared with current on-road technology. Replacing traditional silicon device-based components with more efficient and higher-temperature wide-bandgap (WBG) semiconductor device-based components will enable increased power density. However, meeting the power density target will also require innovative thermal management solutions to increase the heat fluxes dissipated and allow for compact electronics packaging. This project conducts research to develop new power electronics thermal management technologies to increase power density, enable high WBG temperature operation, and decrease cost. The performance (e.g., thermal resistance, pumping power) of the power electronics cooling technologies developed in this project are compared to the performance of current, on-road technology. One of the main challenges to achieving high power densities is associated with packaging high-temperature (up to 250 degrees C) WBG devices near lower-temperature-rated components (e.g., electrical boards and capacitors).

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗

DOE OSTI2021

Baseline Airfoil Cooling Designs For 5-10MW Gas Turbines

This paper describes conventional cooling technologies that have been identified after a thorough review of public literature as a baseline for more detailed analysis and future testing. This effort is unique because the cooling features (i.e., leading edge, mid-chord, and trailing edge) are integrated together within an airfoil of realistic scale. The engineering models that have been developed to characterize the cooling performance for these baseline configurations will be described. It is believed that the cooling designs described in this paper are representative of gas turbines in the 5-10 MWe size range, but not identical to any commercial product. The present effort to establish a state-of-the-art cooling scheme is a first, and necessary, step in an on-going project to identify and test more advanced cooling concepts for CHP systems that are enabled by additive manufacturing.

Straub, Douglas↗

DOE OSTI2021

Baseline Airfoil Cooling Designs For 5-10MW Gas Turbines - Conference Paper

Straub, Douglas↗

DOE OSTI2023

Highly-Efficient Microemulsion-Based Absorption Chillers for HVAC Application

Air conditioning is a necessity to achieve a comfortable, habitable home or office for many places in US. However, vapor compression air conditioners are largely made with chlorofluorocarbon refrigerants, or CFCs, which create problems for a world grappling with climate change. In addition, vapor compression air conditioners are driven by electricity. Cooling and heating represent one-third of building electrical energy consumption in US. An absorption chiller is different to vapor compression chillers or air conditioners because it doesn’t use conventional refrigerants, like CFC. Instead, they may use water as the refrigerant which is mixed with safe and nontoxic absorbents. The research performed in this project advanced the understanding of absorption cooling technology and its application in HVAC. Various technologies were explored to improve the performance of the desorber and absorber components in the absorption chillers.

42 ENGINEERING↗

DOE OSTI2024

Fusion Development and Technology (Final Technical Report for FC02-93ER54186)

The project is divided into three major tasks: 1) Magnet R&D i) Magnets Task 1 - Development of HTS Twisted Stacked-Tape Cable (TSTC) conductors for high field, high current magnets ii) Magnets Task 2– Development of Cryogenic Magnet Cooling Technology iii) Magnets Task 3 - National and International Collaboration 2) Electron Cyclotron Heating (ECH) of plasmas 3) FNSF Liquid Metals Study.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

Design of an optical amplifier for amplified OSC in IOTA facility at Fermilab

Optical stochastic cooling (OSC) is a cutting-edge beam cooling technology to reduce, control the 3 dimensional spread and the motion of particle beams. It has recently been successfully, experimentally, demonstrated in Fermilab's IOTA storage ring, marking a major step forward in beam cooling. OSC has the potential to significantly improve both the performance and flexibility as a beam cooling system. One promising way to boost OSC performance is by adding a high-gain optical amplifier. However, this amplifier must be carefully designed to meet the specific constraints of the OSC system. A major challenge lies in the limited optical delay, which is just 6 mm for the case of IOTA, set by the beam bypass, restricts us to use a short-length gain medium. This, along with IOTA’s high repetition rate and the relatively long duration of the optical pulses, limits the peak power available for the pump laser without damaging the crystal, which is crucial for achieving strong nonlinear gain. Additionally, it's essential to preserve the phase coherence of the undulator radiation during amplification, which further complicates the amplifier design. This report details a specialized amplifier setup that addresses these challenges, includes simulations of the integrated system, and summarizes the latest experimental progress and results.

Mondal, Abhishek [Fermilab]↗

DOE OSTI2025

Realizing Steady-State Microbunching with Optical Stochastic Crystallization

Optical Stochastic Cooling (OSC) is a state-of-the-art beam cooling technology first demonstrated in 2021 at the IOTA storage ring at Fermilab's FAST facility. A second phase of the research program is planned to run in 2026 and will incorporate an optical amplifier to enable significantly increased cooling rates and greater operational flexibility. In addition to beam cooling, an OSC system can be configured to enable advanced control over the phase space of the beam. An example operational mode could enable crystallization, where the particles in a bunch are locked into a self-reinforcing, regular microstructure at the OSC fundamental wavelength; we refer to this as Optical Stochastic Crystallization (OSX). OSX represents a new path toward Steady-State Microbunching (SSMB), which may enable light sources combining the high brightness of a free-electron laser with the high repetition rate of a storage ring. Such a source has applications from the terahertz to the extreme ultraviolet (EUV), including high-power EUV generation for semiconductor lithography. This contribution will discuss the integration of OSX development as part of the OSC program at IOTA. The design of an accelerator lattice to enable the mechanism and associated high fidelity simulations will be shown, and a path to realizing an experimental demonstration will be discussed.

Wallbank, Michael James [Fermilab]↗

DOE OSTI2025

Steady-State Microbunching using Optical Stochastic Cooling

Optical Stochastic Cooling (OSC) is a state-of-the-art beam cooling technology first demonstrated in 2021 at the IOTA storage ring at Fermilab's FAST facility. A second phase of the research program is planned to run in 2026 and will incorporate an optical amplifier to enable significantly increased cooling rates and greater operational flexibility. In addition to beam cooling, an OSC system can be configured to enable advanced control over the phase space of the beam. An example operational mode could enable crystallization, where the particles in a bunch are locked into a self-reinforcing, regular microstructure at the OSC fundamental wavelength; we refer to this as Optical Stochastic Crystallization (OSX). OSX represents a new path toward Steady-State Microbunching (SSMB), which may enable light sources combining the high brightness of a free-electron laser with the high repetition rate of a storage ring. Such a source has applications from the terahertz to the extreme ultraviolet (EUV), including high-power EUV generation for semiconductor lithography. This contribution will discuss the integration of OSX development as part of the OSC program at IOTA. The design of an accelerator lattice to enable the mechanism and associated high fidelity simulations demonstrating the beam dynamics will be shown, and a path to realizing an experimental demonstration will be discussed.

Wallbank, Michael James [Fermilab]↗

DOE OSTI2024

Realizing Steady-State Microbunching with Optical Stochastic Crystallization

Optical Stochastic Cooling (OSC) is a state-of-the-art beam cooling technology first demonstrated in 2021 at the IOTA storage ring at Fermilab's FAST facility. A second phase of the research program is planned to run in early 2025 and will incorporate an optical amplifier to enable significantly increased cooling rates and greater operational flexibility. In addition to beam cooling, an OSC system can be configured to enable advanced control over the phase space of the beam. An example operational mode could enable crystallization, where the particles in a bunch are locked into a self-reinforcing, regular microstructure at the OSC fundamental wavelength; we refer to this as Optical Stochastic Crystallization (OSX). OSX represents a new path toward Steady-State Microbunching (SSMB), which may enable light sources combining the high brightness of a free-electron laser with the high repetition rate of a storage ring. Such a source has applications from the terahertz to the extreme ultraviolet (EUV), including high-power EUV generation for semiconductor lithography. This contribution will discuss the status of the OSC experimental program and its potential to achieve the first demonstration of SSMB during the upcoming experimental run.

Wallbank, M.↗

DOE OSTI2024

Realizing Steady-State Microbunching with Optical Stochastic Crystallization

Optical Stochastic Cooling (OSC) is a state-of-the-art beam cooling technology first demonstrated in 2021 at the IOTA storage ring at Fermilab's FAST facility. A second phase of the research program is planned to run in early 2025 and will incorporate an optical amplifier to enable significantly increased cooling rates and greater operational flexibility. In addition to beam cooling, an OSC system can be configured to enable advanced control over the phase space of the beam. An example operational mode could enable crystallization, where the particles in a bunch are locked into a self-reinforcing, regular microstructure at the OSC fundamental wavelength; we refer to this as Optical Stochastic Crystallization (OSX). OSX represents a new path toward Steady-State Microbunching (SSMB), which may enable light sources combining the high brightness of a free-electron laser with the high repetition rate of a storage ring. Such a source has applications from the terahertz to the extreme ultraviolet (EUV), including high-power EUV generation for semiconductor lithography. This contribution will discuss the status of the OSC experimental program and its potential to achieve the first demonstration of SSMB during the upcoming experimental run.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Dual-Functional Thermocapacitive Heat Pump with Electrochemical Supercapacitors for Building Thermal Management and Energy Storage

Efficient heating and cooling technologies can help reduce the energy consumption and carbon emissions of buildings. This work explores the use of supercapacitive cells in a multifunctional, liquid-regenerated thermocapacitive heat pump that can provide electrical energy storage in addition to heating and cooling. A proof-of-concept prototype based on eight commercial supercapacitors and using deionized water as a liquid regenerator demonstrated cooling and energy storage capabilities. A peak cooling coefficient of performance (COPc) of 0.27 was achieved at a temperature drop of 0.24 K. The highest measured electrical energy storage density of the cells was 5.93 J cm-3, and the highest cooling power delivered relative to the volume of the cells was 0.58 mW cm-3. This work demonstrates the use of electrochemical energy storage devices in multifunctional equipment for thermal management in buildings.

25 ENERGY STORAGE↗

DOE OSTI2026

Revolutionizing thermal Management in Next-Generation AI data centers: Challenges and breakthrough innovations

Data centers (DCs) serve as critical infrastructure for powering the growth and evolution of AI. Next-generation AI DCs present unique challenges in thermal management driven by unprecedented computational demands. This paper provides a comprehensive summary of key stakeholder perspectives on technology gaps, infrastructure requirements, test bed needs, emerging opportunities, and preliminary solutions related to thermal management for AI DCs. It establishes six strategic pillars of thermal management for next generation AI DC: reliability, deployability, efficiency, resilience, measurability, and valorization. The discussion spans a range of critical topics, including advanced cooling technologies, thermal strategies for emerging modular and edge DCs, system-level optimization and control frameworks, infrastructure planning and grid integration designs, benchmarking approaches, and pathways for waste heat recovery and reuse. The proposed research, development, and demonstration efforts are aimed at accelerating the deployment of AI DCs while ensuring energy efficiency, reliability, safety, and regulatory compliance.

Wang, Pengtao [ORNL] (ORCID:0000000214713429)↗

DOE OSTI2024

Power Electronics Manufacturing Improvements for Heavy-Duty Fuel Cell Vehicles

The Marel Power Solutions project, funded by the U.S. Department of Energy under Award DE-SC0023801, focused on advancing manufacturing techniques for power electronics in heavy-duty fuel cell vehicles. The research aimed to enhance system efficiency, reduce costs, and support broader adoption of hydrogen fuel cell technology. Key areas of investigation included power topology, thermal modeling, system architecture, and accessibility through software tools. Key Accomplishments: 1. Power Topology: - Developed an interleaved boost converter with optimized phase count, leveraging Marel’s proprietary Power Stacks. - Achieved reduced parasitic inductance and resistance, enabling high efficiency in DC-DC converters. 2. Thermal Modeling: - Integrated innovative cooling systems into compact Silicon Carbide (SiC) modules. - Simulations demonstrated the ability to dissipate significant heat (up to 7.5 kW), ensuring device reliability under heavy loads. 3. System Architecture: - Utilized simulation tools to analyze the impact of various fuel cell and vehicle parameters on efficiency. - Highlighted the role of smaller, modular improvements, such as enhanced DC-DC converters, in achieving system-wide gains. 4. Accessibility: - Evaluated and implemented MATLAB/Simulink code generation tools for real-world hardware applications. - Demonstrated the potential for rapid prototyping of custom power systems with reduced development costs. Impact and Benefits: - Efficiency and Cost Reduction: Marel’s cooling technology enhances SiC die performance, reducing the number of dies required and overall system size. - Scalability and Flexibility: The innovations support tailored solutions for diverse applications, from mass transit to mining vehicles. - Sustainability: The research promotes the integration of electrification technologies, helping meet rising energy demands sustainably. Conclusion: The project’s outcomes advance the state of power electronics for hydrogen fuel cell vehicles, enabling more efficient, compact, and cost-effective solutions. These developments lay a foundation for future innovation, contributing to the broader adoption of clean energy technologies in transportation and other industries.

08 HYDROGEN↗

DOE OSTI2024

Development of Additive Manufacturing for Ceramic Matrix Composite Vanes

This report discusses the development of additive manufacturing for polymer-derived ceramic materials to create novel cooled gas turbine airfoils made from ceramics. Gas turbine engines have extremely high temperatures in the hot section of the engine that exceed the melting point of nickel superalloy materials that the engine is made from. Advanced cooling technologies have been developed over decades for metallic parts. Ceramic materials have higher temperature capabilities than superalloys, but are difficult to shape in the complex designs used in modern turbines. Several thrusts were investigated during the project, including development of higher material strength resins, improvement of ultraviolet (UV) photopolymerization and post-processing techniques to increase survivability of ceramic parts, thermomechanical modeling of novel ceramic airfoil designs for higher cooling effectiveness, and experimental validation of the modeling and manufacturing in a turbine vane test facility at nondimensional conditions that are relevant to modern gas turbines. Some major findings of the work include a significant increase in ceramic survivability during pyrolysis (a high temperature process that converts the organic material to a ceramic) by adjusting the composition ratios of the resins, as well as a tolulene soak after printing to remove unreacted polymer material. Thermomechanical optimization of the internal cooling structure indicated that a high density pin fin array would enable an 80% increase in overall cooling effectiveness relative to a baseline geometry, which was later verified during experimental testing in a high speed linear cascade. Ceramic vanes were tested at Mach numbers of up to 0.9 which is relevant to modern gas turbines. High temperature capability of the ceramic vanes was not tested in this work.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Ductless Heat Pump Program

The Verde Ductless Heat Pump (DHP) Program expanded access to high-efficiency electric heating and cooling technologies for households in priority communities within the Portland Metro area. Funded by the U.S. Department of Energy’s Building Technologies Office (DE-EE0010132), the program combined residential ductless heat pump deployment with community-based outreach, participant support, contractor partnerships, and system development to improve program delivery.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Exploring the Limits of Cooling for Extreme Heat Flux Applications: Data Centers and Power Electronic

We developed an Extreme Heat Flux Micro-cooler (EHFµ-C) capable of removing heat flux of ~1 kW/cm 2 with a small temperature rise ~10°C. This represents greater than 10× reduction in thermal resistance compared to the state-of-the-art single-phase cooling technologies (~0.5 cm 2 -°C/W) that greatly increases the efficiency, resulting in improved performance and reliability for microprocessors and power electronics. The EHFµ-Cooler utilizes liquid wicking (no pump) and thin-film evaporation in a 30 µm thick wick porous microstructure such as copper inverse opal (CIO), silicon and AlN pin fins along with a 3D manifold (copper wiremesh and silicon) with liquid routing and vapor extraction channels achieving an unprecedented vapor quality ~ >0.9. The proposed EHFµ-Cooler significantly reduces device temperature, resulting in 25-50% improvement in reliability and device performance. Based on very conservative estimates, the total energy saving for data centers due to improved performance can be 6 billion kWh/year (>$300M). Better cooling, leading to more efficient, higher performance and more reliable power electronics, would save the nation 3 Quad of primary energy in 2030. Just for automotive application, a 10% increase in fuel efficiency for SiC-based power electronics equates to >20 million gallons of fuel savings annually. The proposed EHFµ-Cooler technology ensures the United States maintains its technological lead in high-performance computing and high-power electronics, while at the same time improving the energy efficiency, and as a result reducing energy-related emissions such as greenhouse gases.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗