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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
NASA NTRS1976

Classification improvement by optimal dimensionality reduction when training sets are of small size

A computer simulation was performed to test the conjecture that, when the sizes of the training sets are small, classification in a subspace of the original data space may give rise to a smaller probability of error than the classification in the data space itself; this is because the gain in the accuracy of estimation of the likelihood functions used in classification in the lower dimensional space (subspace) offsets the loss of information associated with dimensionality reduction (feature extraction). A number of pseudo-random training and data vectors were generated from two four-dimensional Gaussian classes. A special algorithm was used to create an optimal one-dimensional feature space on which to project the data. When the sizes of the training sets are small, classification of the data in the optimal one-dimensional space is found to yield lower error rates than the one in the original four-dimensional space.

Starks, S. A.↗
DOE OSTI2022

Improved Electrostatic Design of the Jefferson Lab 300 kV DC Photogun and the Minimization of Beam Deflection

An electron beam with high bunch charge and high repetition rate is required for electron cooling of the ion beam to achieve the high luminosity required for the proposed electron-ion colliders. An improved design of the 300 kV DC high voltage photogun at Jefferson Lab was incorporated toward overcoming the beam loss and space charge current limitation experienced in the original design. To reach the bunch charge goal of ~ few nC within 75 ps bunches, the existing DC high voltage photogun electrodes and anode-cathode gap were modified to increase the longitudinal electric field (Ez) at the photocathode. The anode-cathode gap was reduced to increase the Ez at the photocathode, and the anode aperture was spatially shifted with respect to the beamline longitudinal axis to minimize the beam deflection introduced by the geometric asymmetry of the inverted insulator photogun. The electrostatic design and beam dynamics simulations were performed to determine the required modification. Beam-based measurement from the modified gun confirmed the reduction of the beam deflection, which is presented in this contribution.

Mamun, M. A.↗
NASA NTRS1998

Containerless Processing in Reduced Gravity Using the TEMPUS Facility during MSL-1 and MSL-1R

Containerless processing provides a high purity environment for the study of high-temperature, very reactive materials. It is an important method which provides access to the metastable state of an undercooled melt. In the absence of container walls, the nucleation rate is greatly reduced and undercooling up to (Tm-Tn)/Tm approx. equal to 0.2 can be obtained, where Tm and Tn are the melting and nucleation temperatures, respectively. Electromagnetic levitation represents a method particularly well-suited for the study of metallic melts. The TEMPUS (Tiegelfreies ElektroMagnetisches Prozessieren Unter Schwerelosgkeit) facility is a research instrument designed to perform electromagnetic levitation studies in reduced gravity. TEMPUS is a joint undertaking between DARA, the German Space Agency, and the Microgravity Science and Applications Division of NASA. The George C. Marshall Space Flight Center provides the leadership for scientific and management efforts which support the four US PI teams which performed experiments in the TEMPUS facility. The facility is sensitive to accelerations in the 1-10 Hz range. This became evident during the MSL-1 mission. Analysis of accelerometer and video data indicated that loss of sample control occurred during crew exercise periods which created disturbances in this frequency range. Prior to the MSL-1R flight the TEMPUS team, the accelerometer support groups and the mission operations team developed a strategy to provide for the operation of the facility without such disturbances. The successful implementation of this plan led to the highly successful operation of this facility during MSL-1R.

Rogers, Jan R.↗
NASA NTRS2004

The Rate Constant for the Reaction H + C2H5 at T = 295 - 150K

The reaction between the hydrogen atom and the ethyl (C2H3) radical is predicted by photochemical modeling to be the most important loss process for C2H5 radicals in the atmospheres of Jupiter and Saturn. This reaction is also one of the major sources for the methyl radicals in these atmospheres. These two simplest hydrocarbon radicals are the initial species for the synthesis of larger hydrocarbons. Previous measurements of the rate constant for the H + C2H5 reaction varied by a factor of five at room temperature, and some studies showed a dependence upon temperature while others showed no such dependence. In addition, the previous studies were at higher temperatures and generally higher pressures than that needed for use in planetary atmospheric models. The rate constant for the reaction H + C2H5 has been measured directly at T = 150, 202 and 295 K and at P = 1.0 Torr He for all temperatures and additionally at P = 0.5 and 2.0 Torr He at T = 202 K. The measurements were performed in a discharge - fast flow system. The decay of the C2H5 radical in the presence of excess hydrogen was monitored by low-energy electron impact mass spectrometry under pseudo-first order conditions. H atoms and C2H5 radicals were generated rapidly and simultaneously by the reaction of fluorine atoms with H2 and C2H6, respectively. The total rate constant was found to be temperature and pressure independent. The measured total rate constant at each temperature are: k(sub 1)(295K) = (1.02+/-0.24)x10(exp -10), k(sub 1)(202K) = (1.02+/-0.22)x10(exp -10) and k(sub 1)(150K) = (0.93+/-0.21)x10(exp -10), all in units of cu cm/molecule/s. The total rate constant derived from all the combined measurements is k(sub 1) = (l.03+/-0.17)x10(exp -10) cu cm/molecule/s. At room temperature our results are about a factor of two higher than the recommended rate constant and a factor of three lower than the most recently published study.

Pimentel, Andre S.↗
NASA NTRS1997

Constraints on the nucleus and dust properties from mid-infrared imaging of comet Hyakutake

We use Mie scattering theory to determine the expected thermal emission from dust grains in cometary comae and apply these results to mid-infrared images of comet Hyakutake (C/1996 B2) obtained preperihelion in 1996 March. Calculations were performed for dust grains in the size range from 0.1 to 10 micrometers for two different compositions: amorphous olivine (a silicate glass) and an organic residue mixture. The resulting emission efficiencies are complicated functions of wavelength and particle size and are significantly different for the two materials in question. The Hyakutake data set consists of three nights of high-resolution imaging (100-150 km pixel-1 at the comet) of the inner coma at 8.7, 11.7, 12.5, and 19.7 micrometers. Attempts to fit the observed colors (ratios of fluxes at different wavelengths) using a single grain composition failed. However, fits to the data were achieved for all three nights using a mixture of approximately 1 micrometer olivine grains and approximately 7 micrometers organic grains. The resulting olivine mass fraction was between 8% and 16% of the total dust mass-loss rate. We also estimate the radius of the nucleus to be r = 2.1 +/- 0.4 km.

Non-NASA Center↗
NASA NTRS2008

Integrated Vehicle Ground Vibration Testing in Support of NASA Launch Vehicle Loads and Controls Analysis

The National Aeronautics and Space Administration (NASA) Ares Projects Office (APO) is continuing to make progress toward the final design of the Ares I crew launch vehicle and Ares V cargo launch vehicle. Ares I and V will form the space launch capabilities necessary to fulfill NASA's exploration strategy of sending human beings to the Moon, Mars, and beyond. As with all new space vehicles there will be a number of tests to ensure the design can be Human Rated. One of these is the Integrated Vehicle Ground Vibration Test (IVGVT) that will be measuring responses of the Ares I as a system. All structural systems possess a basic set of physical characteristics unique to that system. These unique characteristics include items such as mass distribution, frequency and damping. When specified, they allow engineers to understand and predict how a structural system like the Ares I launch vehicle behaves under given loading conditions. These physical properties of launch vehicles may be predicted by analysis or measured through certain types of tests. Generally, these properties are predicted by analysis during the design phase of a launch vehicle and then verified through testing before the vehicle is Human Rated. The IVGVT is intended to measure by test the fundamental dynamic characteristics of Ares I during various phases of operational/flight. This testing includes excitations of the vehicle in lateral, longitudinal, and torsional directions at vehicle configurations representing different trajectory points. During the series of tests, properties such as natural frequencies, mode shapes, and transfer functions are measured directly. These data will then be used to calibrate loads and Guidance, Navigation, and Controls (GN&C) analysis models for verifying analyses of Ares I. NASA launch vehicles from Saturn to Shuttle have undergone Ground Vibration Tests (GVTs) leading to successful launch vehicles. A GVT was not performed on the unmanned Delta III. This vehicle was lost during launch. Subsequent analyses indicated that had a GVT been conducted on the vehicle, problems with vehicle modes and control may have been discovered and corrected, avoiding loss of the vehicle/mission. This paper will address GVT planning, set-up, conduction and analyses, for the Saturn and Shuttle programs, and also focus on the current and on-going planning for the Ares I and V IVGVT.

Tuma, Margaret L.↗
DOE OSTI2025

Long-Term Photovoltaic System Performance in Cold, Snowy Climates

As countries around the world transition towards renewable energy, there is increasing interest in using photovoltaic (PV) technologies to help decarbonize northern and alpine communities due to their scalability and affordability. However, a barrier to large-scale adoption of PV in cold climates is long-term performance uncertainty under snowfall, freeze-thaw cycles, low temperatures, and high winds. In this work, we provide a comprehensive review of published silicon degradation rates in cold Koppen-Geiger climate classifications of Dfb (humid continental), Dfc (subarctic), and ET (tundra). We first analyze the system degradation rates of three subarctic ground-mounted photovoltaic sites in North America using the RdTools year-on-year method: an Al-BSF double-axis tracking site in Fairbanks, Alaska (65degrees N); a PERC and silicon heterojunction bifacial vertical and south-tilted site in Fairbanks, Alaska; and a PERC south-facing fixed-tilt site in Fort Simpson, Northwest Territories (62degrees N). Degradation rates of these newly analyzed sites vary between -0.4%/year and -1.5%/year. Combining these data with previously reported cold climate degradation rates, we show that the distribution of cold climate degradation peaks at -0.1%/year to -0.2%/year but has a large tail with rates above -0.5%/year. The average reported cold climate degradation rate is -0.45%/year, whereas the median value is -0.33%/year. These results suggest that despite frequent freeze-thaw cycles and potential exposure to high wind and snow loads, PV systems in cold climates tend to degrade slower than PV systems in warmer climates. The limited sample size of reported degradation rates in cold climates (27) motivates the need for further data acquisition and monitoring efforts as new technologies are deployed.

14 SOLAR ENERGY↗
DOE OSTI2021

Dynamic spatial progression of isolated lithium during battery operations

The increasing demand for next-generation energy storage systems necessitates the development of high-performance lithium batteries. Unfortunately, current Li anodes exhibit rapid capacity decay and a short cycle life, owing to the continuous generation of solid electrolyte interface and isolated Li (i-Li). The formation of i-Li during the nonuniform dissolution of Li dendrites leads to a substantial capacity loss in lithium batteries under most testing conditions. Because i-Li loses electrical connection with the current collector, it has been considered electrochemically inactive or ‘dead’ in batteries. In this work, contradicting this commonly accepted presumption, we show that i-Li is highly responsive to battery operations, owing to its dynamic polarization to the electric field in the electrolyte. Simultaneous Li deposition and dissolution occurs on two ends of the i-Li, leading to its spatial progression toward the cathode (anode) during charge (discharge). Revealed by our simulation results, the progression rate of i-Li is mainly affected by its length, orientation and the applied current density. Moreover, we successfully demonstrate the recovery of i-Li in Cu–Li cells with >100% Coulombic efficiency and realize LiNi 0.5 Mn 0.3 Co 0.2 O 2 (NMC)–Li full cells with extended cycle life.

25 ENERGY STORAGE↗
DOE OSTI2024

An Na/TM-site Mg substituted P2-Na 2/3 [Fe 1/3 Mg 1/12 Mn 7/12 ]O 2 cathode with extremely high capacity for sodium-ion batteries

The anionic redox reaction (ARR) has become a hot topic in battery research due to its ability to provide high energy density. Nevertheless, there are still many issues in Na-based layered oxides with the ARR, such as large voltage hysteresis, lattice oxygen loss, irreversible structural changes, and cation migration in the TM layer, resulting in structural collapse and poor electrochemical performance. Herein, a series of Na 2/3 [Fe 1/3 Mg x Mn 2/3–x ]O 2 cathodes are synthesized using a traditional solid-state reaction method. The effectiveness of Mg substitution amounts and site occupancy in regulating the reversibility of the ARR has been explored using various experimental techniques. Surprisingly, the well-designed Na/TM-site Mg substituted P2-Na 2/3 [Fe 1/3 Mg 1/12 Mn 7/12 ]O 2 exhibits an extremely high initial reversible capacity of ~253.21 mA h g –1 , equivalent to ~0.94 e – transfer, which is contributed by both cationic and anionic redox reactions as confirmed by hard X-ray absorption spectroscopy (hXAS) and soft X-ray absorption spectroscopy (sXAS) analyses. In addition, the improved cycling and high-rate performance of the P2-Na 2/3 [Fe 1/3 Mg 1/12 Mn 7/12 ]O 2 are achieved by a well-maintained crystal structure and the highly reversible anionic redox reaction of O 2– /O n– . Finally, these in-depth studies provide crucial knowledge for the development and understanding of cathode materials with a highly reversible ARR for low-cost and high-energy sodium-ion batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Annihilation-limited long-range exciton transport in high-mobility conjugated copolymer films

A combination of ultrafast, long-range, and low-loss excitation energy transfer from the photoreceptor location to a functionally active site is essential for cost-effective polymeric semiconductors. Delocalized electronic wavefunctions along π-conjugated polymer (CP) backbone can enable efficient intrachain transport, while interchain transport is generally thought slow and lossy due to weak chain–chain interactions. In contrast to the conventional strategy of mitigating structural disorder, amorphous layers of rigid CPs, exemplified by highly planar poly(indacenodithiophene-co-benzothiadiazole) (IDT-BT) donor-accepter copolymer, exhibit trap-free transistor performance and charge-carrier mobilities similar to amorphous silicon. Here, we report long-range exciton transport in HJ -aggregated IDTBT thin-film, in which the competing exciton transport and exciton–exciton annihilation (EEA) dynamics are spectroscopically separated using a phase-cycling-based scheme and shown to depart from the classical diffusion-limited and strong-coupling regime. In the thin film, we find an annihilation-limited mechanism with ≪100% per-encounter annihilation probability, facilitating the minimization of EEA-induced excitation losses. In contrast, excitons on isolated IDTBT chains diffuse over 350 nm with 0.56 cm 2 s −1 diffusivity, before eventually annihilating with unit probability on first contact. We complement the pump–probe studies with temperature-dependent photocurrent and EEA measurements from 295 K to 77 K and find a remarkable correspondence of annihilation rate and photocurrent activation energies in the 140 K to 295 K temperature range.

Shi, Yuping (ORCID:0000000318289415)↗
DOE OSTI2024

Corrosion-Resistant Non-Carbon Electrocatalyst Supports for PEFCS

Insufficient durability of commercial catalysts is a persistent issue for PEFC applications.1 Herein, Pt on Nb-doped-TiO 2 is reported as a highly durable electrocatalyst on which the direct 4-electron reduction of oxygen to water is more facile compared to Pt/C. All performance metrics are reported comparing Pt/Nb-TiO2 with a 15% Pt loading, against a commercial Pt/C catalyst (46.5% Pt loading, Tanaka, K. K.). Nb-doped-TiO 2 with high surface area and high electronic conductivity was synthesized using the supercritical fluid method. Initially, the durability of the catalyst was characterized using accelerated stability tests (ASTs) involving 10,000 high potential cycles (DOE/FCCJ protocol) and the Pt/Nb-TiO 2 was found to retain 78% of its initial electrochemically active surface area (ECSA) compared to the 57.6 % retained by Pt/C. These observations were in excellent agreement with previous reports that the Pt particle size of Pt/C grew from 2nm to 8nm during the AST protocol along with severe corrosion and amorphization of the carbon surface.2, 3 TEM and XPS studies of the Pt-Nb-doped-TiO 2 catalyst showed that the Pt particle size grew from 3nm to 6nm and the Nb(IV) and Ti(III) in the support were oxidized to Nb(V) and Ti(IV) after the durability test. Thus, the improvement in Pt/Nb-TiO 2 ECSA retention was attributed to the lower extent of particle growth and lack of oxidative support loss upon oxidation as compared to Pt/C. The oxygen reduction reaction (ORR) performance was characterized by linear polarization using a rotating disk electrode (RDE). The electrochemical surface areas of Pt/Nb-TiO 2 and Pt/C were found to be 48m2·g -1 and 83m2·g -1 respectively, and the mass activity for the ORR at 0.9V vs. RHE were found to be 150 mA·mg-1Pt and 124 mA·mg-1Pt respectively. The improved mass activity on Pt/Nb-TiO 2 was attributed to strong metal support interaction (SMSI) between the Nb-TiO 2 support and the Pt catalyst based on the 625 meV decrease in the binding energy of the Pt4f x-ray photo-electron spectroscopy (XPS) peaks of Pt/Nb-TiO 2 compared to Pt/C. To quantify the impact of the SMSI, a kinetic model was applied to calculate the elementary reaction rate constants for the various steps of the ORR on both catalysts. The reaction rate constant (k1) for the direct 4-electron transfer pathway to produce H 2 O was significantly larger in Pt/Nb-TiO 2 as compared to Pt/C. Thus, the reduction in the electron binding energy as observed in the XPS was found to aid the facile filling of the higher energy 2p orbitals of O 2 thereby leading to improved 4-electron transfer kinetics and improved overall activity.

08 HYDROGEN↗
NASA NTRS1987

Wind tunnel test results of heavy rain effects on airfoil performance

The effects of simulated heavy rain on the aerodynamic characteristics of a NACA 64-210 airfoil section equipped with high-lift devices were investigated in the NASA Langley 14- by 22-Foot Subsonic Tunnel. The experiment was part of an on-going NASA program to determine the effect of heavy rain on airplane performance, and was directed at providing insight into scaling laws for subscale model testing of rain effects. The model used in the investigation had a chord of 2.5 feet, a span of 8.0 feet, and was mounted on the tunnel centerline between two large endplates. A water spray distribution system was located 10 chord lengths upstream of the model. The sensitivity of test results to partial-span coverage of the model in the simulated rain environment as compared to full-span coverage was also investigated. The lift and drag data obtained for the high-lift configuration show excellent repeatability of results compared to the previous data. Results obtained for various spray concentrations and tunnel speeds showed significant losses in maximum lift capability, a decrease in the angle of attack for maximum lift, and an increase in drag as the stimulated rain rate was increased. The test results also indicated that the data were not strongly affected by surface tension effects for the high-lift configuration.

Bezos, G. M.↗
NASA NTRS1993

On-board closed-loop congestion control for satellite based packet switching networks

NASA LeRC is currently investigating a satellite architecture that incorporates on-board packet switching capability. Because of the statistical nature of packet switching, arrival traffic may fluctuate and thus it is necessary to integrate congestion control mechanism as part of the on-board processing unit. This study focuses on the closed-loop reactive control. We investigate the impact of the long propagation delay on the performance and propose a scheme to overcome the problem. The scheme uses a global feedback signal to regulate the packet arrival rate of ground stations. In this scheme, the satellite continuously broadcasts the status of its output buffer and the ground stations respond by selectively discarding packets or by tagging the excessive packets as low-priority. The two schemes are evaluated by theoretical queuing analysis and simulation. The former is used to analyze the simplified model and to determine the basic trends and bounds, and the later is used to assess the performance of a more realistic system and to evaluate the effectiveness of more sophisticated control schemes. The results show that the long propagation delay makes the closed-loop congestion control less responsive. The broadcasted information can only be used to extract statistical information. The discarding scheme needs carefully-chosen status information and reduction function, and normally requires a significant amount of ground discarding to reduce the on-board packet loss probability. The tagging scheme is more effective since it tolerates more uncertainties and allows a larger margin of error in status information. It can protect the high-priority packets from excessive loss and fully utilize the downlink bandwidth at the same time.

Chu, Pong P.↗
NASA NTRS1997

Generic Airplane Model Concept and Four Specific Models Developed for Use in Piloted Simulation Studies

A generic airplane model concept was developed to allow configurations with various agility, performance, handling qualities, and pilot vehicle interface to be generated rapidly for piloted simulation studies. The simple concept allows stick shaping and various stick command types or modes to drive an airplane with both linear and nonlinear components. Output from the stick shaping goes to linear models or a series of linear models that can represent an entire flight envelope. The generic model also has provisions for control power limitations, a nonlinear feature. Therefore, departures from controlled flight are possible. Note that only loss of control is modeled, the generic airplane does not accurately model post departure phenomenon. The model concept is presented herein, along with four example airplanes. Agility was varied across the four example airplanes without altering specific excess energy or significantly altering handling qualities. A new feedback scheme to provide angle-of-attack cueing to the pilot, while using a pitch rate command system, was implemented and tested.

Hoffler, Keith D.↗
NASA NTRS1997

Piloted Simulation Tests of Propulsion Control as Backup to Loss of Primary Flight Controls for a B747-400 Jet Transport

Partial failures of aircraft primary flight control systems and structural damages to aircraft during flight have led to catastrophic accidents with subsequent loss of lives (e.g. DC-10, B-747, C-5, B-52, and others). Following the DC-10 accident at Sioux City, Iowa in 1989, the National Transportation Safety Board recommended 'Encourage research and development of backup flight control systems for newly certified wide-body airplanes that utilize an alternate source of motive power separate from that source used for the conventional control system.' This report describes the concept of a propulsion controlled aircraft (PCA), discusses pilot controls, displays, and procedures; and presents the results of a PCA piloted simulation test and evaluation of the B747-400 airplane conducted at NASA Ames Research Center in December, 1996. The purpose of the test was to develop and evaluate propulsion control throughout the full flight envelope of the B747-400 including worst case scenarios of engine failures and out of trim moments. Pilot ratings of PCA performance ranged from adequate to satisfactory. PCA performed well in unusual attitude recoveries at 35,000 ft altitude, performed well in fully coupled ILS approaches, performed well in single engine failures, and performed well at aft cg. PCA performance was primarily limited by out-of-trim moments.

Bull, John↗
NASA NTRS2011

Sustainability of the Catalytic Activity of a Silica-Titania Composite (STC) for Long-Term Indoor Air Quality Control

TiO2-assisted photocatalytic oxidation (PCO) is an emerging technology for indoor air quality control and is also being evaluated as an alternative trace contaminant control technology for crew habitats in space exploration. Though there exists a vast range of literature on the development of photocatalysts and associated reactor systems, including catalyst performance and performance-influencing factors, the critical question of whether photocatalysts can sustain their initial catalytic activity over an extended period of operation has not been adequately addressed. For a catalyst to effectively serve as an air quality control product, it must be rugged enough to withstand exposure to a multitude of low concentration volatile organic compounds (VOCs) over long periods of time with minimal loss of activity. The objective of this study was to determine the functional lifetime of a promising photocatalyst - the silica-titania composite (STC) from Sol Gel Solutions, LLC in a real-world scenario. A bench-scale STC-packed annular reactor under continuous irradiation by a UV-A fluorescent black-light blue lamp ((lambda)max = 365 nm) was exposed to laboratory air continuously at an apparent contact time of 0.27 sand challenged with a known concentration of ethanol periodically to assess any changes in catalytic activity. Laboratory air was also episodically spiked with halocarbons (e.g., octafluoropropane), organosulfur compounds (e.g., sulfur hexafluoride), and organosilicons (e.g., siloxanes) to simulate accidental releases or leaks of such VOCs. Total organic carbon (TOC) loading and contaminant profiles of the laboratory air were also monitored. Changes in STC photocatalytic performance were evaluated using the ethanol mineralization rate, mineralization efficiency, and oxidation intermediate (acetaldehyde) formation. Results provide insights to any potential catalyst poisoning by trace halocarbons and organosulfur compounds.

Coutts, Janelle L.↗
NASA NTRS2012

A Comparison of Candidate Seal Designs for Future Docking Systems

NASA is developing a new docking system to support future space exploration missions to low Earth orbit, the Moon, and other destinations. A key component of this system is the seal at the main docking interface which inhibits the loss of cabin air once docking is complete. Depending on the mission, the seal must be able to dock in either a seal-on-flange or seal-on-seal configuration. Seal-on-flange mating would occur when a docking system equipped with a seal docks to a system with a flat metal flange. This would occur when a vehicle docks to a node on the International Space Station. Seal-on-seal mating would occur when two docking systems equipped with seals dock to each other. Two types of seal designs were identified for this application: Gask-O-seals and multi-piece seals. Both types of seals had a pair of seal bulbs to satisfy the redundancy requirement. A series of performance assessments and comparisons were made between the candidate seal designs indicating that they meet the requirements for leak rate and compression and adhesion loads under a range of operating conditions. Other design factors such as part count, integration into the docking system tunnel, seal-on-seal mating, and cost were also considered leading to the selection of the multi-piece seal design for the new docking system. The results of this study can be used by designers of future docking systems and other habitable volumes to select the seal design best-suited for their particular application.

Dunlap, Patrick, H., Jr.↗
DOE OSTI2022

Comparative Analysis of Direct and Indirect Cooling of Wide-Bandgap Power Modules and Performance Enhancement of Jet Impingement-Based Direct Substrate Cooling

With the development of high-power and high-torque machines, requirements for high-power density electronics are increasing. Thermal management of such systems requires high heat extraction. Conventional air cooling based heat sinks and cold plate based liquid cooling have their own benefits for various applications but has limitations for high power density applications. The current study explores a jet impingement based direct substrate cooling system that was implemented for a SiC based direct bonded Cu substrate for various power losses. Numerical comparison between jet impingement cooling and conventional horizontal/indirect cooling (pin fin heat sink and genetic algorithm-optimized heat sink) showed that the area weighted average of the heat transfer coefficient (HTC) is high for both horizontal cooling designs, and the local HTC is higher for jet impingement. Design iterations were undertaken to resolve the bottleneck of this cooling system. Increasing the number of nozzles helped to cover more area at the direct bonded Cu bottom plate, which drops the chip temperature considerably. With a constant flow rate, increasing the number of nozzles would decrease local jet velocity, which reduces the heat extraction by jet impingement. This issue can be addressed by reducing the diameter of nozzle but doing so results in a high pressure drop where the design constraint is 2 psi. A flared nozzle design is proposed, which has a higher spreading angle of the jet that increases the flow coverage and reduces the pressure drop of the coolant loop.

Barua, Himel↗