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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 721 records · Page 40

Impact of Accelerated StressTests on SiC MOSFET Precursor Parameters: Preprint

Incorporating SiC power MOSFETs is very attractive for advancing power electronic system performance, yet the system reliability with new devices remains in question. This work presents an overview of accelerated lifetime tests and the packaging and semiconductor failure mechanisms they excite. The experiments explained here includes High Temperature Gate Bias (HTGB), Switching Cycling, Power Cycling, and Thermal Cycling. These experiments stress different failure mechanisms, that show degradation in different device parameters including, but not limited to, threshold voltage and on-resistance. These four experiments help illustrate the spectrum between device and package degradation that can be used to design more reliable power electronic circuits.

33 ADVANCED PROPULSION SYSTEMS↗

Enhanced dielectric properties due to space charge-induced interfacial polarization in multilayer polymer films

We report that with the recent advancement of power electronics, polymer film capacitors have become increasingly important. However, the low temperature rating (up to 85 °C) and low energy density (5 J cm -3 at breakdown) of state-of-the-art biaxially oriented polypropylene (BOPP) films have been limiting factors for advanced power electronics. Based on our recent work, multilayer films (MLFs), which consist of a high energy density polymer [e.g., poly(vinylidene fluoride) (PVDF)] and a high breakdown/low loss polymer [e.g., polycarbonate (PC)], have shown potential to achieve high energy density (13–17 J cm -3 ), enhanced breakdown strength, high temperature tolerance, and low loss simultaneously. In this study, the dielectric properties of PC/PVDF 50/50 32- and 256-layer (32L and 256L) films were investigated. The breakdown strength of the 32L film was as high as 800 MV m -1 at room temperature, as compared to 600 MV m -1 of PVDF and 750 MV m-1 of PC. The temperature rating of the 32L film reached 120 °C, higher than that of BOPP. In addition, it was observed that the 32L film with thicker PC layers exhibited a higher breakdown strength and a lower DC conductivity than the 256L film with thinner PC layers at elevated temperatures. These differences were attributed to the difference in the interfacial polarization of space charges, which was further verified by thermally stimulated depolarization current spectroscopy. In conclusion, we conclude that interfacial polarization endows MLFs with the desirable dielectric properties for next generation film capacitors.

36 MATERIALS SCIENCE↗

Successful completion of a cyclic ground test of a mercury ion auxiliary propulsion system

An engineering model Ion Auxiliary Propulsion System (IAPS) 8-cm thruster (S/N 905) has completed a life test at NASA Lewis Research Center. The mercury ion thruster successfully completed and exceeded the test goals of 2557 on/off cycles and 7057 hr of operation at full thrust. The final 1200 cycles and 3600 hr of the life test were conducted using an engineering model of the IAPS power electronics unit (PEU) and breadboard digital controller and interface unit (DCIU). This portion of the test is described in this paper with a charted history of thruster operating parameters and off-normal events. Performance and operating characteristics were constant throughout the test with only minor variations. The engineering model power electronics unit operated without malfunction; the flight software in the digital controller and interface unit was exercised and verified. Post-test inspection of the thruster revealed facility enhanced accelerator grid erosion but overall the thruster was in good condition. It was concluded that the thruster performance was not drastically degraded by time or cycles. Additional cyclic testing is currently under consideration.

Francisco, David R.↗

Successful completion of a cyclic ground test of a mercury Ion Auxiliary Propulsion System

An engineering model Ion Auxiliary Propulsion System (IAPS) 8-cm thruster (S/N 905) has completed a life test at NASA Lewis Research Center. The mercury ion thruster successfully completed and exceeded the test goals of 2557 on/off cycles and 7057 hr of operation at full thrust. The final 1200 cycles and 3600 hr of the life test were conducted using an engineering model of the IAPS power electronics unit (PEU) and breadboard digital controller and interface unit (DCIU). This portion of the test is described in this paper with a charted history of thruster operating parameters and off-normal events. Performance and operating characteristics were constant throughout the test with only minor variations. The engineering model power electronics unit operated without malfunction; the flight software in the digital controller and interface unit was exercised and verified. Post-test inspection of the thruster revealed facility enhanced accelerator grid erosion but overall the thruster was in good condition. It was concluded that the thruster performance was not drastically degraded by time or cycles. Additional cyclic testing is currently under consideration.

Francisco, David R.↗

Novel Transformer with Variable Leakage and Magnetizing Inductances

This paper introduces the concept of a novel variable inductance transformer (VIT) whose leakage and magnetizing inductances can be varied dynamically and independently to aid the advancement of research in isolated power electronic converters. In this transformer, the leakage inductance can be varied by varying the length of overlap between the primary and secondary windings, while the magnetizing inductance can be varied by varying the air gap between the core legs. Individual controls for the two inductances ensure that one can be varied independent of the other, as needed to satisfy different power conversion objectives. In this paper, the analytical models of the variable leakage and magnetizing inductances are presented. Analytical results are compared with those obtained from Finite Element Method (FEM) and an experimental prototype of a VIT. Analytical solutions of the variable leakage inductance present an error of less than 2.35 % when compared to FEM solutions, while the analytical solutions of the variable magnetizing inductance present a maximum error of 1.82 % when compared to experimental measurements.

image method, leakage inductance, magnetizing indu↗

A 10-kW SiC Inverter with A Novel Printed Metal Power Module With Integrated Cooling Using Additive Manufacturing

With efforts to reduce the cost, size, and thermal management systems for the power electronics drivetrain in hybrid electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs), wide band gap semiconductors including silicon carbide (SiC) have been identified as possibly being a partial solution. This paper focuses on the development of a 10-kW all SiC inverter using a high power density, integrated printed metal power module with integrated cooling using additive manufacturing techniques. This is the first ever heat sink printed for a power electronics application. About 50% of the inverter was built using additive manufacturing techniques.

Inverter↗

Automating Component-Level Stress Measurements for Inverter Reliability Estimation

In the near future, grid operators are expected to regularly use advanced distributed energy resource (DER) functions, defined in IEEE 1547-2018, to perform a range of grid-support operations. Many of these functions adjust the active and reactive power of the device through commanded or autonomous operating modes which induce new stresses on the power electronics components. In this work, an experimental and theoretical framework is introduced which couples laboratory-measured component stress with advanced inverter functionality and derives a reduction in useful lifetime based on an applicable reliability model. Multiple DER devices were instrumented to calculate the additional component stress under multiple reactive power setpoints to estimate associated DER lifetime reductions. A clear increase in switch loss was demonstrated as a function of irradiance level and power factor. This is replicated in the system-level efficiency measurements, although magnitudes were different—suggesting other loss mechanisms exist. Using an approximate Arrhenius thermal model for the switches, the experimental data indicate a lifetime reduction of 1.5% when operating the inverter at 0.85 PF—compared to unity PF—assuming the DER failure mechanism thermally driven within the H-bridge. If other failure mechanisms are discovered for a set of power electronics devices, this testing and calculation framework can easily be tailored to those failure mechanisms.

Flicker, Jack (ORCID:0000000212232154)↗

Degradation Characterization of Thermal Interface Greases: Preprint

Thermal interface materials (TIMs) are used in power electronics packaging to minimize thermal resistance between the heat generating component and the heat sink. Thermal greases are one such class. The conformability and thin bond line thickness (BLT) of these TIMs can potentially provide low thermal resistance throughout the operation lifetime of a component. However, their performance degrades over time due to pump-out and dry-out during thermal and power cycling. The reliability performance of greases through operational cycling needs to be quantified to develop new materials with superior properties. NREL, in collaboration with DuPont, has performed thermal and reliability characterization of several commercially available thermal greases. Initial bulk and contact thermal resistance of grease samples were measured, and then the thermal degradation that occurred due to pump-out and dry-out during temperature cycling was monitored. The thermal resistances of five different grease materials were evaluated using NREL's steady-state thermal resistance tester based on the ASTM test method D5470. Greases were then applied, utilizing a 2.5 cm x 2.5 cm stencil, between invar and aluminum plates to compare the thermomechanical performance of the materials in a representative test fixture. Scanning Acoustic microscopy, thermal, and compositional analyses were performed periodically during thermal cycling from -40 degrees Celcius to 125 degrees Celcius. Completion of this characterization has allowed for a comprehensive evaluation of thermal greases both for their initial bulk and contact thermal performance, as well as their degradation mechanisms under accelerated thermal cycling conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Power distribution for electron beam welding

The power distribution of an electron seam is analyzed. Digital computer techniques are used to evaluate the radial distribution of power detected by a wire probe circulating through the beam. Results are reported.

Edwards, E.↗

ESTIMATING THE PROPERTIES OF HARD X-RAY SOLAR FLARES BY CONSTRAINING MODEL PARAMETERS

We wish to better constrain the properties of solar flares by exploring how parameterized models of solar flares interact with uncertainty estimation methods. We compare four different methods of calculating uncertainty estimates in fitting parameterized models to Ramaty High Energy Solar Spectroscopic Imager X-ray spectra, considering only statistical sources of error. Three of the four methods are based on estimating the scale-size of the minimum in a hypersurface formed by the weighted sum of the squares of the differences between the model fit and the data as a function of the fit parameters, and are implemented as commonly practiced. The fourth method is also based on the difference between the data and the model, but instead uses Bayesian data analysis and Markov chain Monte Carlo (MCMC) techniques to calculate an uncertainty estimate. Two flare spectra are modeled: one from the Geostationary Operational Environmental Satellite X1.3 class flare of 2005 January 19, and the other from the X4.8 flare of 2002 July 23. We find that the four methods give approximately the same uncertainty estimates for the 2005 January 19 spectral fit parameters, but lead to very different uncertainty estimates for the 2002 July 23 spectral fit. This is because each method implements different analyses of the hypersurface, yielding method-dependent results that can differ greatly depending on the shape of the hypersurface. The hypersurface arising from the 2005 January 19 analysis is consistent with a normal distribution; therefore, the assumptions behind the three non-Bayesian uncertainty estimation methods are satisfied and similar estimates are found. The 2002 July 23 analysis shows that the hypersurface is not consistent with a normal distribution, indicating that the assumptions behind the three non-Bayesian uncertainty estimation methods are not satisfied, leading to differing estimates of the uncertainty. We find that the shape of the hypersurface is crucial in understanding the output from each uncertainty estimation technique, and that a crucial factor determining the shape of hypersurface is the location of the low-energy cutoff relative to energies where the thermal emission dominates. The Bayesian/MCMC approach also allows us to provide detailed information on probable values of the low-energy cutoff, E{sub c} , a crucial parameter in defining the energy content of the flare-accelerated electrons. We show that for the 2002 July 23 flare data, there is a 95% probability that E{sub c} lies below approximately 40 keV, and a 68% probability that it lies in the range 7-36 keV. Further, the low-energy cutoff is more likely to be in the range 25-35 keV than in any other 10 keV wide energy range. The low-energy cutoff for the 2005 January 19 flare is more tightly constrained to 107 {+-} 4 keV with 68% probability. Using the Bayesian/MCMC approach, we also estimate for the first time probability density functions for the total number of flare-accelerated electrons and the energy they carry for each flare studied. For the 2002 July 23 event, these probability density functions are asymmetric with long tails orders of magnitude higher than the most probable value, caused by the poorly constrained value of the low-energy cutoff. The most probable electron power is estimated at 10{sup 28.1} erg s{sup -1}, with a 68% credible interval estimated at 10{sup 28.1}-10{sup 29.0} erg s{sup -1}, and a 95% credible interval estimated at 10{sup 28.0}-10{sup 30.2} erg s{sup -1}. For the 2005 January 19 flare spectrum, the probability density functions for the total number of flare-accelerated electrons and their energy are much more symmetric and narrow: the most probable electron power is estimated at 10{sup 27.66{+-}0.01} erg s{sup -1} (68% credible intervals). However, in this case the uncertainty due to systematic sources of error is estimated to dominate the uncertainty due to statistical sources of error.

79 ASTRONOMY AND ASTROPHYSICS↗

FY13 Annual Report:APEEM Components Analysis and Evaluation

The objectives of this evaluation is to Support the evaluation of current and proposed electric machine and power electronics technologies in a vehicle context to understand the applicability of a particular powertrain technology to a given vehicle and to determine areas/regions for component design improvement based upon system usage patterns; and Enhance the current benchmarking and prototype evaluation capabilities of DOE APEEM programs with the addition of transient-capable testing facilities for power electronics and electric machinery components.

33 ADVANCED PROPULSION SYSTEMS↗

Transport and breakdown analysis for improved figure-of-merit for AlGaN power devices

Mobility and critical electric field for bulk AlxGa1-xN alloys across the full composition range (0 ≤ x ≤ 1) are analyzed to address the potential application of this material system for power electronics. Calculation of the temperature-dependent electron mobility includes the potential limitations due to different scattering mechanisms, including alloy, optical polar phonon, deformation potential, and piezoelectric scattering. The commonly used unipolar figure of merit (appropriate for vertical-device architectures), which increases strongly with increasing mobility and critical electric field, is examined across the alloy composition range to estimate the potential performance in power electronics applications. Alloy scattering is the dominant limitation to mobility and thus also for the unipolar figure of merit. However, at higher alloy compositions, the limitations due to alloy scattering are overcome by increased critical electric field. These trade-offs, and their temperature dependence, are quantified in the analysis.

Coltrin, Michael E.↗

Electrical Power Conversion of River and Tidal Power Generator

As renewable generation has become less expensive during recent decades, and it becomes more accepted by the global population, the focus on renewable generation has expanded to include new types with promising future applications, such as river and tidal generation. Although the utilization of power electronics and electric machines in industry is phenomenal, the emphasis on system design is different for various sectors of industry. In precision control, robotics, and weaponry, the design emphasis is on accuracy and reliability with less concern for the cost of the final product. In energy generation, the cost of energy is the prime concern; thus, capital expenditures (CAPEX) and operations and maintenance expenditures (OPEX) are the major design objectives. This paper describes the electrical power conversion aspects of river and tidal generation. Although modern power converter control is available to control the generation side, the design was chosen on the bases of minimizing the CAPEX and OPEX; thus, the architecture is simple and modular for ease of replacement and maintenance. The power conversion is simplified by considering a simple diode bridge and a DC-DC power converter to take advantage of abundant and low-cost photovoltaic inverters that have well-proven grid integration characteristics (i.e., the capability to produce energy with good power quality and control real power and voltage on the grid side).

16 TIDAL AND WAVE POWER↗

Multi-Port Autonomous Reconfigurable Solar Power Plant

As the penetration level of power electronics increases and remote photovoltaic (PV) generation is integrated into the alternating current (ac) grid, the short-circuit ratio (SCR) at the point of interconnection of a hybrid PV–energy storage system (ESS) plant may be low. Additionally, the inertia of the alternating current (ac) grid may be low. The low SCRs and inertias can lead to reliability challenges in the power grid. These operating conditions require additional reinforcements, such as synchronous condensers, static var compensators, static synchronous compensators, and high-voltage direct current (HVdc) links/grids. HVdc links or grids may also provide the additional capability of connecting the plant to asynchronous grids and/or connecting asynchronous grids, among others. This scenario leads to discrete development of solar inverters, energy storage inverters, HVdc converters, and several transformers. Some of the problems associated with this discrete development and inverter-based generation include increased cost, lower reliability, and reduced efficiency associated with duplication of power electronics (PEs); competing controls of several individual discrete inverter-based generators due to the presence of multiple PEs, which leads to derating of the system; and transient stability problems arising from inverter-based generation, such as voltage/frequency events leading inverter shutdowns, voltage instability and control interactions in the formed weak grid, and harmonics caused by resonances of multiple inverters.

14 SOLAR ENERGY↗

High-power liquid-lithium jet target for neutron production

A compact liquid-lithium target (LiLiT) was built and tested with a high-power electron gun at the Soreq Nuclear Research Center. The lithium target, to be bombarded by the high-intensity proton beam of the Soreq Applied Research Accelerator Facility (SARAF), will constitute an intense source of neutrons produced by the {sup 7}Li(p,n){sup 7}Be reaction for nuclear astrophysics research and as a pilot setup for accelerator-based Boron Neutron Capture Therapy. The liquid-lithium jet target acts both as neutron-producing target and beam dump by removing the beam thermal power (>5 kW, >1 MW/cm{sup 3}) with fast transport. The target was designed based on a thermal model, accompanied by a detailed calculation of the {sup 7}Li(p,n) neutron yield, energy distribution, and angular distribution. Liquid lithium is circulated through the target loop at ∼200 °C and generates a stable 1.5 mm-thick film flowing at a velocity up to 7 m/s onto a concave supporting wall. Electron beam irradiation demonstrated that the liquid-lithium target can dissipate electron power areal densities of >4 kW/cm{sup 2} and volume power density of ∼2 MW/cm{sup 3} at a lithium flow of ∼4 m/s while maintaining stable temperature and vacuum conditions. The LiLiT setup is presently in online commissioning stage for high-intensity proton beam irradiation (1.91–2.5 MeV, 1–2 mA) at SARAF.

43 PARTICLE ACCELERATORS↗

A Guide to Current Limiting and Stability with Grid-Forming Inverters

The electric power grid is changing. For many decades, the synchronous generator - an electromechanical device invented in 1887 - has been the workhorse and backbone of power grids across the globe. Our entire infrastructure is built around it. But times change, and so does the power grid. Since the early 21st century, we have seen a gradual shift in modern power grids away from synchronous generators to ones dominated by power electronic inverter-based resources (IBRs). Sources such as photovoltaics, wind turbines, battery storage, fuel cells, and other technologies like high-voltage DC transmission interconnections all rely on an inverter to connect and interface with the grid. They are increasingly being installed on the grid to augment, or even replace, traditional energy sources. This change is a fundamental shift that brings tremendous technical challenges and questions: Can a power grid remain stable with many more inverter-based resources? How do we avoid more blackouts on the grid? How do we keep the grid secure and resilient during disturbances? After all, power electronic inverters are nothing like the big, rotating, iron-and-copper machines that the grid heavily relies on. Many of these questions can be answered by using grid-forming (GFM) inverters, yet many research challenges remain. This document explores GFM inverters and how they can help stabilize the future grid, especially during disturbances and contingencies. It summarizes a two-year research and development fellowship program at NREL. We point interested readers to more detailed works developed during the project along the way. Let's dive in

24 POWER TRANSMISSION AND DISTRIBUTION↗

pnnl/pecblocks

ConverterBlocks uses the output of detailed electromagnetic transient (EMT) simulations to produce generalized block diagram models of power electronic systems. The process uses deep learning with customized block architectures. The outputs are reduced-order models that meet specified accuracy requirements, while providing important advantages over the original EMT models: ConverterBlock models have fewer nodes and can take longer time steps, resulting in shorter simulation times ConverterBlock models are continuously differentiable, making them compatible with control design methodsGeneralized block diagram modeling of power electronic converters for grid solar and storage applications.

McDermott, Tom↗

Three-phase Four-leg Inverter LabVIEW FPGA Control Code [SWR-16-26]

In the area of power electronics control, Field Programmable Gate Arrays (FPGAs) have the capability to outperform their Digital Signal Processor (DSP) counterparts due to the FPGA’s ability to implement true parallel processing and therefore facilitate higher switching frequencies, higher control bandwidth, and/or enhanced functionality. National Instruments (NI) has developed two platforms, Compact RIO (cRIO) and Single Board RIO (sbRIO), which combine a real-time processor with an FPGA. The FPGA can be programmed with a subset of the well-known LabVIEW graphical programming language. The use of cRIO and sbRIO for power electronics control has developed over the last few years to include control of three-phase inverters. Most three-phase inverter topologies include three switching legs. The addition of a fourth-leg to natively generate the neutral connection allows the inverter to serve single-phase loads in a microgrid or stand-alone power system and to balance the three-phase voltages in the presence of significant load imbalance. However, the control of a four-leg inverter is much more complex. In particular, instead of standard two-dimensional space vector modulation (SVM), the inverter requires three-dimensional space vector modulation (3D-SVM). The candidate software implements complete control algorithms in LabVIEW FPGA for a three-phase four-leg inverter. The software includes feedback control loops, three-dimensional space vector modulation gate-drive algorithms, advanced alarm handling capabilities, contactor control, power measurements, and debugging and tuning tools. The feedback control loops allow inverter operation in AC voltage control, AC current control, or DC bus voltage control modes based on external mode selection by a user or supervisory controller. The software includes the ability to synchronize its AC output to the grid or other voltage-source before connection. The software also includes provisions to allow inverter operation in parallel with other voltage regulating devices on the AC or DC buses. This flexibility allows the Inverter to operate as a stand-alone voltage source, connected to the grid, or in parallel with other controllable voltage sources as part of a microgrid or remote power system. In addition, as the inverter is expected to operate under severe unbalanced conditions, the software includes algorithms to accurately compute real and reactive power for each phase based on definitions provided in the IEEE Standard 1459: IEEE Standard Definitions for the Measurement of Electric Power Quantities Under Sinusoidal, Nonsinusoidal, Balanced, or Unbalanced Conditions. Finally, the software includes code to output analog signals for debugging and for tuning of control loops. The software fits on the Xilinx Virtex V LX110 FPGA embedded in the NI cRIO-9118 FPGA chassis, and with a 40 MHz base clock, supports a modulation update rate of 40 MHz, user-settable switching frequencies and synchronized control loop update rates of tens of kHz, and reference waveform generation, including Phase Lock Loop (PLL), update rate of 100 kHz.

Martin, Gregory↗