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At least 1,585 records · Page 88
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

The emergence of wide-bandgap (WBG) devices in power electronics packages has brought significant attention to the reliability and thermal performance of the bonded interfaces. These interfaces, such as die-attach and substrate-attach, need to withstand the severe stress induced on them by the high-temperature (> 200°C) operation of the WBG devices. Sintered silver and transient liquid phase alloys are key bonded interfaces that can enable the high-temperature operation of WBG devices, however it is essential to evaluate their reliability and study the possible failure mechanisms before they can be used in power electronics packages. Sintered silver is already being adopted in commercial packages as a die-attach, but large-area substrate-attach offers additional reliability challenges. In this project, we investigate the reliability of these interface materials under accelerated thermal cycling and correlate these results with finite element simulations to develop lifetime prediction models. The failure mechanisms of these bonded interfaces are also studied.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

Wide-bandgap devices have pushed the operational limit of semiconductor devices in automotive power electronics packages to higher temperatures (>200 C). While a higher efficiency can be achieved through the use of wide-bandgap devices, the entire package must be re-designed with components that can withstand the higher temperature limits. Sintered silver and transient liquid phase bonds are potential candidates as bonded materials for use in higher temperatures however, the underlying mechanics of deformation under thermal loads and the resulting failure mechanisms in these materials are not well understood. Accelerated experiments conducted at NREL reveal that high-lead solder joints have better reliability than sintered silver under extreme thermal cycling conditions. Furthermore, efforts to develop a crack propagation model for the high-temperature materials are described.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

High temperature operation of wide bandgap devices continue to be a challenge for the power electronics packages. Thermal performance and reliability are important factors that determine the viability of a bonded interface for operation at high temperatures. In this presentation, we present the technical approach and key results from the research on sintered silver, transient liquid phase alloy, and polymeric materials. A lifetime prediction model that incorporates the thermomechanical behavior of sintered silver at 200C was developed. The copper-aluminum transient alloy completed 350 thermal cycles from -40C to 200C and little increase in the defect level was observed. In addition to material research, we initiated a time-series analysis on the scanning acoustic microscope images of eutectic solder to explore statistical forecasting methods and machine learning techniques. Initial results that report the accuracy of a few different statistical models are presented.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2013

Prototype Development of Remote Operated Hot Uniaxial Press (ROHUP) to Fabricate Advanced Tc-99 Bearing Ceramic Waste Forms - 13381

The objective of this senior student project is to design and build a prototype construction of a machine that simultaneously provides the proper pressure and temperature parameters to sinter ceramic powders in-situ to create pellets of rather high densities of above 90% (theoretical). This ROHUP (Remote Operated Hot Uniaxial Press) device is designed specifically to fabricate advanced ceramic Tc-99 bearing waste forms and therefore radiological barriers have been included in the system. The HUP features electronic control and feedback systems to set and monitor pressure, load, and temperature parameters. This device operates wirelessly via portable computer using Bluetooth{sup R} technology. The HUP device is designed to fit in a standard atmosphere controlled glove box to further allow sintering under inert conditions (e.g. under Ar, He, N{sub 2}). This will further allow utilizing this HUP for other potential applications, including radioactive samples, novel ceramic waste forms, advanced oxide fuels, air-sensitive samples, metallic systems, advanced powder metallurgy, diffusion experiments and more. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Development of Stable Solidification Method for Insoluble Ferrocyanides-13170

The development of stable solidification method of insoluble ferrocyanides sludge is an important subject for the safety decontamination in Fukushima NPP-1. By using the excellent immobilizing properties of zeolites such as gas trapping ability and self-sintering properties, the stable solidification of insoluble ferrocyanides was accomplished. The immobilization ratio of Cs for K{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O saturated with Cs{sup +} ions (Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O) was estimated to be less than 0.1% above 1,000 deg. C; the adsorbed Cs{sup +} ions are completely volatilized. In contrast, the novel stable solid form was produced by the press-sintering of the mixture of Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O and zeolites at higher temperature of 1,000 deg. C and 1,100 deg. C; Cs volatilization and cyanide release were completely depressed. The immobilization ratio of Cs, under the mixing conditions of Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O:CP= 1:1 and calcining temperature: 1,000 deg. C, was estimated to be nearly 100%. As for the kinds of zeolites, natural mordenite (NM), clinoptilolite (CP) and Chabazite tended to have higher immobilization ratio compared to zeolite A. This may be due to the difference in the phase transformation between natural zeolites and synthetic zeolite A. In the case of the composites (K{sub 2-X}Ni{sub X/2}[NiFe(CN){sub 6}].nH{sub 2}O loaded natural mordenite), relatively high immobilization ratio of Cs was also obtained. This method using zeolite matrices can be applied to the stable solidification of the solid wastes of insoluble ferrocyanides sludge. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2013

Properties measurements of (U{sub 0.7}Pu{sub 0.3})O{sub 2-x} in PO{sub 2}-controlled atmosphere

The investigation of physical properties of uranium and plutonium mixed oxide (MOX) fuels is important for the development of fast reactor fuels. It is well known that MOX is a nonstoichiometric oxide, and the physical properties change drastically with the Oxygen-to-Metal (O/M) ratio. A control technique for O/M ratio was established for measurements of high temperature properties of uranium and plutonium mixed oxide fuels. Sintering behavior, thermal expansion and O/M change of (U{sub 0.7}Pu{sub 0.3})O{sub 2.00} and (U{sub 0.7}Pu{sub 0.3})O{sub 1.99} were investigated in PO{sub 2}-controlled atmosphere which was controlled by H{sub 2}/H{sub 2}O gas system. Sintering behavior changed drastically with O/M ratio, and shrinkage of (U{sub 0.7}Pu{sub 0.3})O{sub 2.00} was faster and more advanced at lower temperatures as compared with (U{sub 0.7}Pu{sub 0.3})O{sub 1.99}. Thermal expansion was observed to be slightly increased with decreasing O/M ratio. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Fabrication of advanced accident tolerant U-Si fuel forms

Prospective advanced accident tolerant UN-USi fuel forms for light-water reactors are being studied at Los Alamos National Laboratory. In this paper we present a recent effort to fabricate and characterize U{sub 3}Si{sub 5} and UN-U{sub 3}Si{sub 5} fuel. The U{sub 3}Si{sub 5} is prepared by arc-melting stoichiometric amounts of uranium and silicon metals. The arc melting process consists of cutting U metal plate into small pieces that can be placed in a tri-arc furnace for melting. The material is slowly heated until a uniform melt of the U and Si is achieved. The fabrication of the U{sub 3}Si{sub 5} pellets followed a conventional cold-press and sinter process. As for the fabrication of UN-U{sub 3}Si{sub 5}, the uranium nitride (UN) feedstock powder was synthesized using carbothermic reduction nitridation. The UN is milled and sieved to sub-74 μm. The UN was mixed with EBS (ethylene bis-stearamide) and milled for 45 minutes. The UN-EBS was combined with 10 wt.% U{sub 3}Si{sub 5} powder (equivalent to 15 vol.% in UN) and additional EBS. The fabrication of the UN-U{sub 3}Si{sub 5} pellets followed a conventional cold-press and sinter process similar to that used to fabricate the U{sub 3}Si{sub 5} pellets. A sample UN-U{sub 3}Si{sub 5} pellet was cross-sectioned, ground, and polished for optical microscopy. The UN and U{sub 3}Si{sub 5} phases are apparent as well as pores and micro-cracks. The affect of micro-cracking on fuel performance is unknown and should be assessed during post-irradiation examination.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Sol-gel deposited transducers characteristics: A weight percent study - 15718

Monitoring functional machinery components that operate at elevated temperatures is costly and time consuming. This work explores leave in place composite transducers for high temperature monitoring of machinery components. A theoretical model was developed utilizing software provided by NASA. This model was then compared to the experimental results. The objective is to determine the characteristics of a set of spray-on composite transducers to identify the ideal transducer for any situation where a certain specification is made: - Operating temperature; - Signal amplitude/Signal to noise ratio; - Specific material property. The transducer is fabricated through a sol-gel deposition process that utilizes spraying the transducer onto the substrate. A sol-gel solution containing bismuth titanate is mixed with a combination of bismuth titanate and lead zirconate titanate(PZT) powders to create a composite transducer. Typical sintering methods have proved to be destructive and difficult to handle for the sol-gel deposition method; however, induction sintering has proved effective. -d{sub 33} decreases with increasing weight percent of bismuth titanate -the maximum usable temperature increases with increasing weight percent bismuth titanate -signal amplitude is also higher with increasing weight percent of bismuth titanate The ideal composition for the best signal amplitude and the highest operating temperature has been shown to be pure bismuth titanate; however, if the properties of the transducer are of utmost importance including conductivity and density then PZT should be added to increase these properties. The theoretical NASA Micromechanical Analysis Code by Generalized Method of Cell model has been validated through the experimental results of these experiments. Now that the composition of the transducer has been optimized to a specific application the future work is comprised of: - Utilizing the information to evaluate wall thickness - Integrating the optimized transducer with a wireless system for remote monitoring of mechanical component - Establishing a field deposition method for the spray-on transducer.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Low Melting Temperature Glass for Immobilisation of Contaminated Zeolitic Ion Exchangers from Fukushima - 16494

The clean-up of the Fukushima Daiichi site continues to generate large volumes of spent adsorbents which need to be disposed of permanently, one of the candidates is a low temperature immobilisation process to avoid volatilising radioactive Cs and Sr species. To this end an immobilisation process with a maximum temperature of 600 deg. C was developed by sintering model waste with glass frit to form a dense Glass Composite Material (GCM) wasteform. A zeolitic model wasteform, chabazite, was sintered with two lead-based glass compositions, lead borosilicate (PBS) and a lead borate (PB) glass composition, at a maximum temperature of 600 deg. C. Full encapsulation of the zeolitic wasteform was achieved for waste-loadings up to 40 wt.% in PBS and 30 wt.% in PB in all cases, with both GCM systems showing foaming. PBS GCM formation was successful at a maximum of 600 deg. C, while the PB GCM formation was shown to be possible at a maximum temperature of 550 deg. C. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Neutron Irradiation Effects on Thermal and Mechanical Properties of NITE-SiC

Among the myriad of methods to produce SiC, only a few result in a stoichiometric and crystalline SiC that exhibits stability after radiation damage at temperatures beyond 200 deg. C. High purity SiC processed via chemical vapor deposition (CVD) is the best example of such a material. Another processing method, named nano-infiltration transient eutectic-forming (NITE) SiC, also yields a radiation stable material. It is a fabrication strategy that takes advantage of liquid-phase sintering to yield dense SiC. Specifically, SiC nanopowder feedstock mixed thoroughly with oxide additives are sintered at high-temperature (T<1850 deg. C). This maximum temperature is too low to result in significant creep or grain growth in SiC-based materials, and therefore allows for encapsulation of SiC fibers or SiC coated fuel particles in the NITE SiC matrix. Neutron irradiation effects in NITE-SiC-based materials (composites, monolithic materials, and some with surrogate fuel particles) have been studied to a limited extent. The goal of this study was to examine neutron irradiation effects at two different doses on five different NITE-SiC variants at two different temperatures. Volumetric swelling, degradation of thermal conductivity, and evolution in mechanical properties are reported accordingly.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

Advanced packaging technologies are currently being designed and developed by the power electronics industry however, the maximum operating temperature is still limited to 175 degrees Celsius for the silicon carbide devices. Bonded materials such as sintered copper and polymeric materials are potential candidates for high temperature operation, but it is critical to characterize and evaluate its reliability under harsh operating conditions. In this project, we discuss the results of the accelerated experiments conducted on sintered copper and polymeric materials. Additionally, a novel framework to develop the lifetime prediction model of bonded interfaces through employing statistical and machine learning models are described. In this task, scanning acoustic microscope images of bonded interfaces obtained under thermal cycling experiments are used as the data.

ENGINEERING↗
DOE OSTI2020

3D Ion-Conducting, Scalable, and Mechanically Reinforced Ceramic Film for High Voltage Solid-State Batteries

Concerning the safety aspects of Li+ ion batteries, an epoxy-reinforced thin ceramic film (ERTCF) is prepared by firing and sintering a slurry-casted composite powder film. The ERTCF is composed of Li + ion conduction channels and is made of high amounts of sintered ceramic Li 1+ x Ti 2-x Al x (PO 4 ) 3 (LATP) and epoxy polymer with enhanced mechanical properties for solid-state batteries. The two- and three-dimensional characterizations are conducted not only for showing continuous Li+ ion channels thorough LATP ceramic channels with over 10-4 S cm-1 of ionic conductivity but also to investigate small amounts of epoxy polymer with enhanced mechanical properties. Solid-state Li + ion cells are fabricated using the ERTCF and they show initial charge–discharge capacities of 139/133 mAh g -1 . Furthermore, the scope of the ERTCF is expanded to high-voltage (>8 V) solid-state Li + ion batteries through a bipolar stacked cell design. Hence, it is expected that the present investigation will significantly contribute in the preparation of the next generation reinforced thin ceramic film electrolytes for high-voltage solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Reversible Phase Transitions Enable Cyclic Isothermal CO 2 Capture in Redox‐Activated Perovskite‐Structured Sorbents

Sorption‐enhanced steam reforming and gasification using CO 2 sorbents enable the production of H 2 ‐rich syngas from carbonaceous feedstocks but are limited by significant temperature swings and sintering‐induced activity loss. Perovskite‐structured oxides are presented herein as sintering‐resistant, redox‐activated isothermal CO 2 sorbents capable of overcoming these challenges by releasing lattice oxygen to partially oxidize the carbonaceous feedstock while capturing CO 2 , shifting equilibrium toward H 2 production. Building on this, the structural and thermodynamic impact of Fe doping on the CO 2 sorption properties of SrMn 1‐ x Fe x O 3‐ δ is investigated for sorption‐enhanced reforming. Experimental results demonstrate that these sorbents enable isothermal production of high‐quality, H 2 ‐enriched syngas from carbonaceous feedstocks. Laboratory and synchrotron‐based powder X‐ray diffraction analyses, coupled with density functional theory calculations, reveal the structural dynamics and energy landscape of the SrMn 1‐ x Fe x O 3‐ δ perovskite system under reaction conditions, elucidating the solid‐state reaction pathway and the effect of Fe doping on the extent of carbonation.

CO2 capture↗
DOE OSTI2022

Experimental validation of multiphysics model simulations of the thermal response of a cement clinker rotary kiln at laboratory scale

Abstract An increasing demand for buildings, transportation systems and civil infrastructure development has driven expansion of cement consumption world‐wide, producing a significant increase in related global energy demand. With approximately 7% of the world‐wide industrial energy consumption (10.7 exajoules [EJ]), the cement industry is the third most energy intensive industrial processes and a key component for concrete, the most consumed composite material in the global construction industry. In cement manufacturing, the cement kiln accounts for most of the energy consumption in the production process. As the heart of a cement plant, the cement kiln is where the kiln feed primarily containing calcium oxide (CaO), silica (SiO 2 ), alumina (Al 2 O 3 ), and iron (Fe 2 O 3 ) are thermally and chemically transformed into clinker minerals. The presented work developed a multiphysics model, designed and built a laboratory‐scale rotary cement clinker kiln, and produced cement clinker at laboratory‐scale. The model was developed to study the interaction between the various thermal, fluid dynamic and chemical interactions involved in the sintering process used to form Portland cement clinker in an effort to reduce energy use. The analytical model was validated through experimental testing using a unique laboratory‐scale rotary cement kiln developed during the investigation. Also demonstrated was the feasibility of producing clinker at laboratory scale. This modeling and lab scale tests were designed to better understand the clinker sintering process so that operational and quality decisions can be made to optimize energy consumption without compromising cement clinker quality. The computational fluid dynamics modeling was developed in COMSOL Multiphysics 6.0. The characteristics of the combustion fluid flow, concentration of species, temperature and heat transfer were studied for a turbulent flow of methane (CH 4 ) gas and oxygen (O 2 ). Theory suggests that heat transfer impacts the cement production process but the multiphysics model more accurately describes the convection, conduction, and radiant heat transfer in the kilning process and thus allows for a better understanding of the energy exchange driving the chemical reactions that produce Portland cement. Clinker minerals were formed because of appropriate burning conditions implemented during experimental model validation.

Tabares, Juan David↗
DOE OSTI2017

Bimetallic Ag-Pt Sub-nanometer Supported Clusters as Highly Efficient and Robust Oxidation Catalysts

A combined experimental and theoretical investigation of Ag-Pt sub-nanometer clusters as heterogeneous catalysts in the CO -> CO2 reaction (COox) is presented. Ag9Pt2 and Ag9Pt3 clusters are size-selected in the gas phase, deposited on an ultrathin amorphous alumina support, and tested as catalysts experimentally under realistic conditions and by first-principles simulations at realistic coverage. Insitu GISAXS/TPRx demonstrates that the clusters do not sinter or deactivate even after prolonged exposure to reactants at high temperature, and present comparable, extremely high COox catalytic efficiency. Such high activity and stability are ascribed to a synergic role of Ag and Pt in ultranano-aggregates, in which Pt anchors the clusters to the support and binds and activates two CO molecules, while Ag binds and activates O-2, and Ag/Pt surface proximity disfavors poisoning by CO or oxidized species.

Ab initio calculations↗
DOE OSTI2020

Highly Ordered Carbon Coating Prepared with Polyvinylidene Chloride Precursor for High‐Performance Silicon Anodes in Lithium‐Ion Batteries

Abstract A highly ordered carbon structure based on polyvinylidene chloride precursor has been developed to host silicon nanoparticles. The stoichiometric ratio of sacrificial H and Cl elements facilitated full utilization of the carbon content of the precursor that produced robust carbon coatings on silicon nanoparticles with excellent mechanic properties and electrochemical stabilities. The optimal sintering temperature and carbon content have been investigated. When evaluated as the anode of a lithium‐ion battery (LIB), the Si : C 1 : 2 composite sintered at 800 °C (SiC12‐800) provided excellent capacity retention of 85 % at 0.1 C after 50 cycles with an enhanced CE, which reached 99 % only after 10 cycles. The SiC12‐800 electrode maintained a specific capacity of 709.2 mAh/g after 300 cycles at 0.3 C, and delivered a high rate performance of 737.9 mAh/g and 485.6 mAh/g at 5 C and 10 C, respectively. The results indicate that polymer precursors with stoichiometric ratio of sacrificial elements have high potential for generating highly robust carbon coatings for silicon anodes in high energy density LIBs.

Zhou, Shuo↗