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DOE OSTI2021

Structure-Property Relationships of Additively Manufactured Ni-Nb Alloys [Slides]

In this work, scratch and nanoindentation testing was used to determine hardness, fracture toughness, strain rate sensitivity, and activation volumes on additively manufactured graded and uniform Ni-Nb bulk specimens. Characterization showed the presence of a two phase system consisting of Ni 3 Nb and Ni 6 Nb 7 intermetallics. Intermetallics were multimodal in nature, having grain and cell sizes spanning from a few nanometers to 10s of micrometers. The unique microstructure resulted in impressively high hardness, up to 20 GPa in the case of the compositionally graded sample. AM methods with surface deformation techniques are a useful way to rapidly probe material properties and alloy composition space.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Structure-Property Relationships of Additively Manufactured Ni-Nb Alloys [Slides]

36 MATERIALS SCIENCE↗

DOE OSTI2022

Advancing Platooning with ADAS (Advanced Driver-Assistance Systems) Control Integration and Assessment

Application of Cooperative Adaptive Cruise Control (CACC) to heavy duty trucks known as truck platooning has shown fuel economy improvements on the test track under ideal driving conditions. However, limited test data is available to assess the truck platooning under real-world driving conditions. Under this Cummins-led project that was funded by the U.S. Department of Energy, truck platooning with CACC has been tested on a real-world interstate highway and the results of the project are reviewed in this report. At first, the real-world driving conditions were characterized using National Renewable Energy Laboratory (NREL) Fleet DNA database to define test factors, including route, terrain, and highway traffic. Afterward, both test track and on-highway testing guided by SAE J1321 procedures were conducted to assess truck platooning under controlled and real-world driving conditions. On-highway testing was done on a highway route in Indiana, consisting of low, medium, and high road grade segments. The highway test results of 2-truck and 3-truck platooning showed considerably reduced fuel savings compared to the controlled test track data, which mainly stems from the traffic or high-grade portions of the route. However, integration of Cummins powertrain and vehicle eco-driving features such as predictive cruise control and neutral coasting called ADEPT™ on the lead truck showed an improvement of fuel saving for the trucks in CACC operation. Furthermore, the importance of tire connectivity in efficient and safe operation of the trucks in platooning is characterized.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Summary of Development for Structural Component Modeling in Fiscal Year 2022

This report summarizes efforts performed during Fiscal Year 2022 to develop capabilities for modeling structural component degradation in support of the U.S. Department of Energy's Nuclear Energy Advanced Modeling and Simulation Program. These efforts were centered around development of capabilities for the Grizzly code. Efforts focused both on foundational engineering-scale analysis capabilities for damage and shell formulations and on material-scale tools for accounting for irradiation effects in Grade 91 steel. A major outcome of this effort was the development of a general-purpose tool for nonlocal averaging of material properties, which enabled nonlocal damage models. In addition, the applicability of the shell elements in MOOSE has been expanded to allow modeling a wider range of component geometries and using a wide variety of material models. For irradiation effects on materials, a previously developed cluster dynamics model for light water reactor pressure vessel steels has been adapted for application to Grade 91 alloy. This work builds on prior efforts to build a flexible, capable code for addressing a variety of aging and component performance issues in nuclear power plant structural components.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Recommended Representative Isotopic Compositions for Potential VTR Pu Supplies

This document recommends isotopic compositions to represent selected Pu supplies that might be made available for use in VTR driver fuel. These compositions are intended to be conservative representations suitable for determination of environmental impacts associated with use of the selected Pu supplies, but not upper bounds of all possible compositions. The selected Pu supplies under consideration are themselves representations of a more complicated set of possibilities, defined in a manner to allow efficient but conservative analysis of impacts. The source definitions to be considered are as follows: 1) Foreign sources of reactor-grade plutonium. This material would be provided as polished material in an oxide form and is assumed to be transported from Europe (France or England); 2) Domestic, non-weapon sources of plutonium such as unused FFTF fuel, Hanford metal (stored at SRS), and various oxides; 3) Domestic sources of weapons-grade plutonium, including metal from dismantled pits and otherwise excess to stockpile needs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

FY 23 Filtration of Hanford Tank 241-SY-101 Supernatant at 16 °C

Approximately 9 liters of supernatant from Hanford waste tank 241-SY-101 was delivered by Washington River Protection Solutions to the Radiochemical Processing Laboratory (RPL) at Pacific Northwest National Laboratory. The thirty-six SY-101 sample bottles were comprised of six sets of six samples, with each set pulled from a unique tank sampling level. Prior to testing, samples from each level were composited to provide nominally level-independent feed for dead end filtration and ion exchange testing. The composited 241-SY-101 supernatant was chilled to 16 °C for 1 week prior to testing. Filtration testing was then conducted using a backpulse dead-end filter (BDEF) system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the RPL. This was done to provide waste processing benchmarks for 200 West Area wastes in the West Area Risk Management project. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 . During filtration of the differential pressure required to effect filtration at 0.065 gpm/ft 2 increased little over the filtration campaign and never reached 2 psid (the Tank Side Cesium Removal system action limit). This indicates that the Media Grade 5 filter should perform well when processing SY-101 supernatant. After completing filtration of the SY-101 feed, the filter was cleaned. Solids concentrated from the backpulse solutions displayed calcium phosphate, aluminum oxides, aluminum-chromium nanoparticle agglomerates. Electron diffraction was used to determine the types of phases that were present in the solids. Most of the phases found were only weakly crystalline, possibly owing to their rapid precipitation during the process water treatment. The identifications of the phases therefore are tentative.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Conversion of METL Diagnostic Flowmeters to Permanent Magnet Based Electromagnetic Flowmeters

The Mechanisms Engineering Test Loop (METL) uses three flowmeters to monitor sodium circulation through the main loop, the Cold Trap leg, and the Plugging Meter leg. When constructed, the Cold Trap flowmeter (CTFM) and Plugging Meter flowmeter (PMFM) were equipped with permanent magnets and Hall Sensors. By October of 2019, during normal operations, both the CTFM and PMFM failed, producing either erroneous or zero signals. Repairs to the flowmeters were attempted in January of 2020 but failed to resolve the issues. Therefore, starting in March of 2021, a plan was developed to convert the installed flowmeters to more robust permanent magnet based electromagnetic flowmeters (EMFMs). The Cold Trap EMFM (CT EMFM) and Plugging Meter EMFM (PM EMFM) were fully installed by August of 2021. Initial testing and commissioning were completed in November of 2021. Finally, the first calibration runs were finished in March of 2022. This report discusses the design, conversion, and calibration of the as-built CTFM and PMFM to robust permanent magnet based EMFMs. During the design phase, theoretical models were used to estimate the signal output and required magnet sizes. Then, the CTFM and PMFM were disassembled and converted to EMFMs. After commissioning, the CT EMFM and PM EMFM were calibrated using a ‘Time Transfer Procedure’ carried out with METL Expansion Vessels and Test Vessel Two. The accuracy of the calibration was estimated through an uncertainty analysis. Finally, the report describes some lessons learned for future flowmeter conversions and follow-up work. In total, both METL EMFM’s met the desired performance targets. Testing data showed that the METL EMFMs provide a output signal of roughly 2 mV at 1 GPM and 250 °C. During calibration, flowrates between 0.7 GPM and 2.4 GPM were achieved. In this flow range, calibration coefficients of 0.485 and 0.935 were measured as with errors ranging from 15-5% and 16-5% for the CT EMFM and PM EMFM, respectively. Above 1.5 GPM, the error was assumed to be about 5% for both METL EMFMs. Several points will be considered for future follow-up work on the METL EMFM’s. First, the signal noise issues in the PM EMFM will be addressed. It is likely the source of the noise is due to some stray EMF from a heater. Secondly, the NdFeB magnets will be replaced with a grade that has a Curie temperature above 80 °C. For example, a few grades of NeFeB magnets have Curie temperatures which exceed 150 °C and some SmCo magnets have Curie temperatures as high as 500 °C. Third, more calibration runs will be completed in the range of 0.5-2.5 GPM. This will further improve the accuracy of the calibration coefficient. Fourth, calibration runs will be completed up to 5 GPM. This requires a larger pressure relief valve to be installed on the Expansion Vessel and Test Vessel 2, as well as a revised calibration procedure. Lastly, calibration runs will be completed to account for cold spots in the system, which reduced the inlet temperature of the METL EMFMs. Overall, these points will improve the calibration coefficients derived in this work and also improve the performance of the METL EMFMs.

42 ENGINEERING↗

DOE OSTI2023

Report on initial development of a database of nuclear graphite characteristics based on microstructural characterization

This report outlines the current and future efforts to produce a comprehensive library of microstructures of nuclear graphite and carbon-based materials that are candidate materials for nuclear applications in the United States. This library must contain extensive characterizations of unirradiated graphite materials, a guide to some of the techniques used to characterize graphite, a compendium of characterization data of neutron-irradiated or oxidized material, and a compendium of microstructural information of carbon-based materials. These characterization efforts are being conducted at various length scales to understand these complex materials’ local structure and property relationships. Achieving this goal requires further developing or adapting advanced characterization techniques that capture graphite’s most relevant characteristics. Some of the general objectives of this project are to aid with the material selection, licensing, management, and core assessments of a graphite core by documenting the unirradiated microstructure of relevant grades or by characterizing the evolution of the microstructure under the reactor environment. Moreover, this project aims to provide additional information, guidelines for characterizing graphite, and a protocol to assess a nuclear graphite grade. This report also summarizes some of the initial results and some of the techniques commonly used to characterize nuclear graphite.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Baseline Characterization Database Verification Report - NBG-18 Billet 635-14

The purpose of this Engineering Calculations and Analysis Report is to present the data being collected in the Baseline Graphite Characterization program, which is directly tasked with supporting the Idaho National Laboratory’s (INL’s) research and development efforts on the Next Generation Nuclear Plant (NGNP)/Very High Temperature Reactor (VHTR)/Advanced Reactor Technology (ART). This program is populating a comprehensive database that will reflect the baseline properties of nuclear-grade graphite regarding individual grade, billet, and position within individual billets. The physical and mechanical property information being collected will be transferred to the NGNP Data Management and Analysis System (NDMAS), and from that database will help populate handbook of property data available to member nations of the Generation IV International Forum (GIF).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Additive Manufacturing of Dissolvable Mandrels

ORNL collaborated with Mitsubishi Chemical America to investigate different grades of vinyl alcohol co-polymers as a potential feedstock material for large-scale material extrusion additive manufacturing (AM). Dissolvable polymers and can find potential applications in AM tooling for complex, hollow, and trapped composite structures without the need for specialized molds and tools. This CRADA Phase I work involved analysis of three different developmental grades of vinyl alcohol co-polymers for thermal and rheological properties, followed by print trials on the Big Area Additive Manufacturing (BAAM) system using these materials. Finally, printed part properties, including mechanical and thermal performance, as well as dissolvability were evaluated. The properties and performance evaluated in this phase of the project have provided guidelines to further develop these vinyl alcohol co-polymers to enable large-scale printing at high deposition rates and obtain parts that satisfy high temperature molds and dies requirements.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Additively Manufactured, Lightweight, Low-Cost Composite Vessels for Compressed Natural Gas Fuel Storage

This project will develop a process to combine AM via direct ink writing (DIW) technology for CFC printing and to use design optimization tools pioneered at LLNL, with advances in resin/composite formulation enabled by chemical and nano-material modification to produce lightweight low-cost CNG tanks. Our approach will yield sub-scale prototype composite pressure tanks equivalent to Type-5 CNG vessel designs that demonstrate a potential cost-benefit advantage. Central to our vision is using agile AM and design based on computationally informed DIW of both short and continuous CF, further coupled with high-performance thermoset polymer matrixes modified by emergent nanomaterials. Our single-stage, multi-material AM technology, combined with a decreased volume fraction of CF and an increased proportion of economically advantaged short fiber, all together drive the reduction in manufacturing time and overall cost. Importantly, reductions in continuous fiber and overall fiber volume fraction will be achieved without detriment to the mechanical strength of the composite vessel. This will be achieved by employing a single process using multi materials grading involving a thermoset resin “ink” modified with aligned nanoplatelets to leverage the efficient tortuous-path gas barrier effect, printed as an inner flexible gas barrier as the initial stage in our manufacturing process before compositionally grading the AM feedstock in real-time to transition to a rigid, structural CF-filled resin. The proposed hybrid construction is projected to achieve pressure ratings at a service range of 2,900–3,600 psi with a 3× burst safety factor comparable to conventional filament-wound composite tanks with an estimated 30–50% reduction in total manufacturing cost.

03 NATURAL GAS↗

DOE OSTI2024

Update on Activities Related to the Library of Graphite Microstructures

This report provides an overview and update of the ongoing efforts to create a comprehensive library of microstructures for nuclear graphite and carbon-based materials under consideration for nuclear applications. The library includes data on microstructural characterization of unirradiated graphite materials, a guide to the techniques used to analyze graphite (which complements the ASME guidelines and ASTM standards), a summary of characterization data for neutron-irradiated or oxidized material, and a compendium of microstructural information for carbon-based materials. These efforts are being conducted at various length scales for the filler and binder phases in graphite to better understand graphite’s local structure and property relationships. This report is a follow-up to the previous milestone report titled Report on initial development of a database of nuclear graphite characteristics based on microstructural characterization, ORNL/TM/-2023/2992, published in July 2023.The effort to develop the library of microstructures supports the US Department of Energy Office of Advanced Reactor Technologies program objectives of aiding the material selection, licensing, management, and core assessments of a graphite core by documenting the unirradiated microstructure of relevant grades or characterizing the microstructure’s evolution under the reactor environment. Additionally, this project aims to provide (1) information and guidelines for the characterizing of graphite and (2) a protocol to assess a nuclear graphite grade.

36 MATERIALS SCIENCE↗

DOE OSTI2024

In-Situ Bioleaching of Manganese by Dissimilatory Reduction

This report describes the development of a biological leaching process for recovery of manganese from low-grade ores, with a high degree of selectivity against contaminants such as iron. This results in the production of manganese that is suitable for battery manufacture and other electrical applications. The leaching process makes use of a community of metal reducing organisms that solubilize manganese at a pH of approximately 4.5. These organisms are nourished by simple organic molecules such as acetate that are generated by decomposition of biomass. A series of long-term laboratory experiments were carried out to determine the necessary operating parameters, followed by construction of a small pilot plant processing approximately 100 kg of ore. This pilot unit was operated for two years, demonstrating the ability to consistently produce high-grade manganese at a commercially viable rate.

25 ENERGY STORAGE↗

DOE OSTI2024

Hawaii Solar Desalination Project

This project built the world’s largest Forward Osmosis (FO) solar thermal desalination plant at the NELHA Hawaii Ocean Science and Technology Park for a high visibility “on sun” demonstration of seawater desalination for agricultural applications. The project included re-commissioning an existing 2MW micro-dish solar thermal array and coupling it to a next-generation 500m3/day FO system. The purpose of the project was to validate FO at commercial scale; to verify that the water produced is safe for potential downstream agricultural users; to gather data on capital cost, energy consumption and operating expense for the technology; and to demonstrate that FO can be successfully coupled to low-grade thermal resources. The plant implemented advancements in FO component technology, including hot nano-filtration, polymeric heat exchangers, draw solutions, and improved FO membranes, and operated from June 2022 to September 2023 - producing 30gpm of permeate water. Thermal energy was below 30kWh/m 3 during operation, establishing a new benchmark in thermal desalination technology, with recovery rates at times exceeding 65%, well above what commercial RO systems can achieve. Combining the plant capital cost (CAPEX) and the operating expenses (OPEX) yields a Levelized Cost of Water (LCOW) that is competitive with existing carbon-intensive technologies such as RO. The ability of the plant to operate from a renewable resource paves the way toward a low-carbon desalination future using low-grade thermal resources.

14 SOLAR ENERGY↗

DOE OSTI2024

Development of Graphite Thermal and Mechanical Modeling Capabilities in Grizzly

Nuclear-grade graphites are used extensively in the core designs of multiple types of advanced nuclear reactors. In the reactor environment, graphite is exposed over long durations to extreme conditions, including high temperatures, radiation and potentially molten salt and oxygen. Exposure to these conditions can cause several degradation mechanisms in graphite, including nonuniform volumetric strains induced by irradiation and thermal expansion, which lead to stresses that can compromise the performance of graphite components. Evaluating component integrity, predicting component performance over the reactor lifetime, and developing design standards all require robust tools for predicting fracture initiation and propagation in graphite structural components in nuclear reactors. This report documents progress in an ongoing effort to develop modeling and simulation tools in the Grizzly code for predicting the performance of graphite exposed to reactor conditions. Recent developments include a set of thermal and mechanical models that now include the IG-110, NBG-18, and H-451 graphite grades. Improvements have also been made to a nonlinear damaged plasticity model applicable to predicting damage under tension and compression to quasibrittle materials, including graphite. In addition, enhancements have been made to the extended finite element method implementation targeted at simulating graphite fracture. These include new capabilities for crack nucleation in the interior of a solid body, improved treatment of crack nucleation on free surfaces, and more robust modeling approaches for crack growth approaching free surfaces or other cracks.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Filtration of Hanford Tank 241-AN-107 Supernatant at 16 °C

Approximately 9 liters of supernatant from Hanford waste tank 241-AN-107 was delivered by Washington River Protection Solutions to the Radiochemical Processing Laboratory (RPL) at Pacific Northwest National Laboratory. The thirty-six AN-107 sample bottles consisted of six sets of six samples, with each set pulled from a unique tank sampling level. Prior to testing, samples from each level were composited to provide nominally level-independent feed for dead end filtration and ion exchange testing. The composited 241-AN-107 supernatant was chilled to 16 °C for 1 week prior to testing. Filtration testing was then conducted using a backpulse dead-end filter (BDEF) system equipped with a feed vessel and a Mott inline filter Model 6610 (Media Grade 5) in the hot cells of the RPL. The purpose of this testing is to a) demonstrate dead-end filtration (DEF) of AN-107 feed at reduced temperature to obtain prototypic tank side cesium removal (TSCR) flux rates and identify issues that may impact filtration after dilution to 5.5M Na, and b) provide feed for a follow on ion exchange unit operation. The feed was filtered through the BDEF system at a targeted flux of 0.065 gpm/ft 2 . During filtration the differential pressure required to effect filtration at 0.065 gpm/ft 2 was slow to increase for most of the filtration campaign. After all the feed bottles had been pumped into the slurry reservoir, the bottoms of the bottles were added to the reservoir and transmembrane pressure (TMP) reached 2.0 psid (the TSCR action limit). The prototypic filter cleaning process was unable to effectively restore filter performance, and cleaning with oxalic acid was required before flow through the filter could be restored. This indicates that the Media Grade 5 filter may require an alternative cleaning protocol when processing AN-107 supernatant. After completing filtration of the AN-107 feed, the filter was cleaned. Solids concentrated from the backpulse solutions were composed of natrophosphate, Mn-Fe phases, and fluoro-natrophosphate that occurred as particle agglomerates. The individual particles were in some cases 100s of micrometers across which is consistent with prior observations from AN-107 supernate waste characterizations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

SMART SiC Power ICs: Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (Final Technical Report)

This collaborative project was initiated with the goal of developing Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (SMART SiC Power ICs). In pursuit of this objective, innovative designs and fabrication processes were implemented, enabling the development of large-scale (>1 cm²) SiC Complementary Metal-Oxide-Semiconductor (CMOS) integrated circuits and high-voltage (400–600 V) lateral power MOSFETs (HV-LDMOS) on 150 mm 4H-SiC substrates. The resulting SMART SiC Power ICs are tailored to support a wide range of applications requiring diverse voltage and power levels, including automotive systems, industrial equipment, electronic data processing, energy harvesting, and power conditioning. To achieve the proposed ‘SMART’ technology for SiC ICs, the team focused on 1) the Development of highly scalable CMOS (with high channel mobilities for n-type and p-type MOSFETs), LDMOS (~600V, 10A rated), and IC technologies, 2) Establishment of a manufacturable process baseline in a production-grade-, 150mm, SiC fabrication facility, and 3) Demonstration of SMART SiC ICs. The project initially comprised of fabricating 5 lots. In lot 1 monolithic integration using a single process was achieved. Here, we were able to successfully accomplish Integrated HV NMOSFET with LV CMOS on N-epi/N+ Substrate. The HV NMOS demonstrated a Breakdown Voltage (BV) more than 600V. Circuit demonstration of CMOS was also another achievement from this lot. In lot 2, priority was in place for isolation and integration. Here we addressed the isolation concerns and integrated the HV NMOS and LV CMOS using the N-epi/P-epi/N+ substrate. Similar to the lot 1, we were able to achieve a BV of 600 V for HV NMOS. Optimized gate oxide process with high channel mobilities, better gate oxide reliability, development of SPICE models, successful ohmic process development, novel wafer area saving design layouts, P+ isolation schemes with channeling implantations and high temperature operational circuits demonstrations are some of the key highlights from lot 1 and lot2. In lot 3, discrete device performances of HV NMOS with a BV ~700V and reliable LV CMOS performances were achieved. Also, novel architectural solutions were successfully implemented to suppress the electric field crowding at the gate oxide for reliable operations. In lot 4, half bridge power driver ICs with a conversion efficiency of (target 90% to 95%) in the 1-5MHz switching frequency range for output power between 25 W to 3 kW have been included in. However, due to the unfortunate events of sudden foundry shutdown (SiCamore Semi) the processing of lot 4 wafers came to a complete stop (January 2024). Arrangements have recently been made to shift the fabrication to another foundry, General Electric Aerospace. The fabrication process now on course (as of December 2024). Characterizations are delayed due to this unfortunate circumstance. The proposed trench architectural-based devices and ICs (lot 5) underwent modifications from the original project proposal. This change was necessitated by limitations in the availability of trench-based processes at commercial production-grade fabrication facilities in the US. Apart from above achievements, a Process Development Kit (PDK) was successfully developed for planar type SiC CMOS/LDMOS.

42 ENGINEERING↗