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NASA NTRS1996

Chip-on-Board Technology 1996 Year-end Report (Design, Manufacturing, and Reliability Study)

The major impetus for flight qualifying Chip-On-Board (COB) packaging technology is the shift in emphasis for space missions to smaller, better, and cheaper spacecraft and satellites resulting from the NASA New Millenium initiative and similar requirements in DoD-sponsored programs. The most important benefit that can potentially be derived from miniaturizing spacecraft and satellites is the significant cost saving realizable if a smaller launch vehicle may be employed. Besides the program cost saving, there are several other advantages to building COB-based space hardware. First, once a well-controlled process is established, COB can be low cost compared to standard Multi-Chip Module (MCM) technology. This cost competitiveness is regarded as a result of the generally greater availability and lower cost of Known Good Die (KGD). Coupled with the elimination of the first level of packaging (chip package), compact, high-density circuit boards can be realized with Printed Wiring Boards (PWB) that can now be made with ever-decreasing feature size in line width and via hole. Since the COB packaging technique in this study is based mainly on populating bare dice on a suitable multi-layer laminate substrate which is not hermetically sealed, die coating for protection from the environment is required. In recent years, significant improvements have been made in die coating materials which further enhance the appeal of COB. Hysol epoxies, silicone, parylene and silicon nitride are desirable because of their compatible Thermal Coefficient of Expansion (TCE) and good moisture resistant capability. These die coating materials have all been used in the space and other industries with varying degrees of success. COB technology, specifically siliconnitride coated hardware, has been flown by Lockheed on the Polar satellite. In addition, DARPA has invested a substantial amount of resources on MCM and COB-related activities recently. With COB on the verge of becoming a dominant player in DoD programs, DARPA is increasing its support of the availability of KGDs which will help decrease their cost. Aside from the various major developments and trends in the space and defense industries that are favorable to the acceptance and widespread use of'COB packaging technology, implementing COB can be appealing in other aspects. Since the interconnection interface is usually the weak link in a system, the overall circuit or system reliability may actually be improved because of the elimination of a level of interconnect/packaging at the chip. With COB, mixing packaging technologies is possible. Because some devices are only available in commercial plastic packages, populating a multi-layer laminate substrate with both bare dice and plastic-package parts is inevitable. Another attractive feature of COB is that re-workability is possible if die coating is applied only on the die top. This method allows local replacement of individual dice that were found to be defective instead of replacing an entire board. In terms of thermal management, unpackaged devices offer a shorter thermal resistance path than their packaged counterparts thereby improving thermal sinking and heat removal from the parts.

Le, Binh Q.↗

NASA NTRS1993

Design Tool

Developed under a Small Business Innovation Research (SBIR) contract, RAMPANT is a CFD software package for computing flow around complex shapes. The package is flexible, fast and easy to use. It has found a great number of applications, including computation of air flow around a Nordic ski jumper, prediction of flow over an airfoil and computation of the external aerodynamics of motor vehicles.

Source record↗

NASA NTRS2019

User Manual for Physical Scalars and Plotting Tools in Scala

An open-source scalar package and associated software tools have been developed in the Scala programming language, including plotting tools based on the free GRACE plotting package. The scalar package represents physical scalars and can help to prevent errors involving physical units in engineering and scientific computation. The scalar package includes a complete implementation of the standard SI metric system of units and many common non-metric units. The design also allows users to easily de ne a specialized or reduced set of physical units for any particular application or domain. The scalar package can be used in two different modes: one mode provides unit compatibility checking but is slower, and the other mode bypasses the compatibility checks but is much faster and still prevents the most common type of unit error. Switching between the two modes requires no changes in the user's code, making it convenient and usable with no significant performance penalty for even the most computationally intensive applications.

Paielli, Russell A.↗

NASA NTRS2020

Mars Science Helicopter Conceptual Design

Robotic planetary aerial vehicles increase the range of terrain that can be examined, compared to traditional landers and rovers, and have more near-surface capability than orbiters. Aerial mobility is a promising possibility for planetary exploration as it reduces the challenges that difficult obstacles pose to ground vehicles. The first use of a rotorcraft for a planetary mission will be in 2021, when the Mars Helicopter technology demonstrator will be deployed from the Mars 2020 rover. The Jet Propulsion Laboratory and NASA Ames Research Center are exploring possibilities for a Mars Science Helicopter, a second-generation Mars rotorcraft with the capability of conducting science investigations independently of a lander or rover (although this type of vehicle could also be used assist rovers or landers in future missions). This report describes the conceptual design of Mars Science Helicopters. The design process began with coaxial-helicopter and hexacopter configurations, with a payload in the range of two to three kg and an overall vehicle mass of approximately twenty kg. Initial estimates of weight and performance were based on the capabilities of the Mars Helicopter. Rotorcraft designs for Mars are constrained by the dimensions of the aeroshell and lander for the trip to the planet, requiring attention to the aircraft packaging in order to maximize the rotor dimensions and hence overall performance potential. Aerodynamic performance optimization was conducted, particularly through airfoils designed specifically for the low Reynolds number and high Mach number inherent to operation on Mars. Rotor structural designs were developed that met blade frequency and weight targets, subject to material stress limits. The final designs show a substantial capability for science operations on Mars: a 31 kg hexacopter that fits within a 2.5 m diameter aeroshell could carry a 5 kg payload for 10 min of hover time or over a range of 5 km.

Wayne Johnson↗

NASA NTRS2010

Development of a Fan for Future Space Suit Applications

NASA's next generation space suit system will place new demands on the fan used to circulate breathing gas through the ventilation loop of the portable life support system. Long duration missions with frequent extravehicular activities (EVAs), the requirement for significant increases in reliability and durability, and a mission profile that imposes strict limits on weight, volume and power create the basis for a set of requirements that demand more performance than is available from existing fan designs. This paper describes the development of a new fan to meet these needs. A centrifugal fan was designed with a normal operating speed of approximately 39,400 rpm to meet the ventilation flow requirements while also meeting the aggressive minimal packaging, weight and power requirements. The prototype fan also operates at 56,000 rpm to satisfy a second operating condition associated with a single fan providing ventilation flow to two spacesuits connected in series. This fan incorporates a novel nonmetallic "can" to keep the oxygen flow separate from the motor electronics, thus eliminating ignition potential. The nonmetallic can enables a small package size and low power consumption. To keep cost and schedule within project bounds a commercial motor controller was used. The fan design has been detailed and implemented using materials and approaches selected to address anticipated mission needs. Test data is presented to show how this fan performs relative to anticipated ventilation requirements for the EVA portable life support system. Additionally, data is presented to show tolerance to anticipated environmental factors such as acoustics, shock, and vibration. Recommendations for forward work to progress the technology readiness level and prepare the fan for the next EVA space suit system are also discussed.

Paul. Heather L.↗

NASA NTRS1994

Review of European microgravity measurements

AA In a French/Russion cooperation, CNES developed a microgravity detection system for analyzing the Mir space station micro-g-environment for the first time. European efforts to characterize the microgravity (1/9) environment within a space laboratory began in the late seventies with the design of the First Spacelab Mission SL-1. Its Material Science Double Rack was the first payload element to carry its own tri-axial acceleration package. Even though incapable for any frequency analysis, the data provided a wealth of novel information for optimal experiment and hardware design and operations for missions to come. Theoretical investigations under ESA contract demonstrated the significance of the detailed knowledge of micro-g data for a thorough experiment analysis. They especially revealed the high sensitivity of numerous phenomena to low frequency acceleration. Accordingly, the payloads of the Spacelab missions D-1 and D-2 were furnished with state-of-the-art detection systems to ensure frequency analysis between 0.1 and 100 Hz. The Microgravity Measurement Assembly (MMA) of D-2 was a centralized system comprising fixed installed as well as mobile tri-axial packages showing real-time data processing and transmission to ground. ESA's free flyer EURECA carried a system for continuous measurement over the entire mission. All EURECA subsystems and experimental facilities had to meet tough requirements defining the upper acceleration limits. In a French/Russion cooperation, CNES developed a mi crogravity detection system for analyzing the Mir space station micro-g-environment for the first time. An approach to get access to low frequency acceleration between 0 and 0.02 Hz will be realized by QSAM (Quasi-steady Acceleration Measurement) on IML-2, complementary to the NASA system Spacelab Acceleration Measurement System SAMS. A second flight of QSAM is planned for the Russian free flyer FOTON.

Hamacher, Hans↗

NASA NTRS1985

Structural Tailoring of SSME Blades (vanes)

The engine blade design optimization program STAEBL (Structural Tailoring of Engine Blades) is available at the NASA Lewis computer facility. The analysis capabilities of this program were extended to typical loading conditions for SSME turbopump blades including thermal and pressure loading. Input files for representative SSME blade designs were developed and sample optimization studies for these blades completed. The structural tailoring program combines a general optimization package and a finite element blade analysis package. The analysis package's capabilities include natural frequency, maximum stress, and forced response computation, and fatigue life and flutter analysis. Optimization is performed using the feasible directions method. The current design is modified by perturbing the design variables so that the design constraints are satisfied while the objective function, such as blade weight, is reduced at the maximum rate. The program's geometric design variables include blade thickness distribution, thickness to chord ratios, and root chord.

Rubinstein, R.↗

NASA NTRS1986

Vector-matrix-quaternion, array and arithmetic packages: All HAL/S functions implemented in Ada

The HAL/S avionics programmers have enjoyed a variety of tools built into a language tailored to their special requirements. Ada is designed for a broader group of applications. Rather than providing built-in tools, Ada provides the elements with which users can build their own. Standard avionic packages remain to be developed. These must enable programmers to code in Ada as they have coded in HAL/S. The packages under development at JPL will provide all of the vector-matrix, array, and arithmetic functions described in the HAL/S manuals. In addition, the linear algebra package will provide all of the quaternion functions used in Shuttle steering and Galileo attitude control. Furthermore, using Ada's extensibility, many quaternion functions are being implemented as infix operations; equivalent capabilities were never implemented in HAL/S because doing so would entail modifying the compiler and expanding the language. With these packages, many HAL/S expressions will compile and execute in Ada, unchanged. Others can be converted simply by replacing the implicit HAL/S multiply operator with the Ada *. Errors will be trapped and identified. Input/output will be convenient and readable.

Klumpp, Allan R.↗

NASA NTRS2010

Hollow Fiber Flight Prototype Spacesuit Water Membrane Evaporator Design and Testing

The spacesuit water membrane evaporator (SWME) is being developed to perform thermal control for advanced spacesuits and to take advantage of recent advances in micropore membrane technology. This results in a robust heat-rejection device that is potentially less sensitive to contamination than is the sublimator. The Membrana Celgard X50-215 microporous hollow-fiber (HoFi) membrane was selected after recent extensive testing as the most suitable candidate among commercial alternatives for continued SWME prototype development. The current design was based on a previous design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape. This was developed into a full-scale prototype consisting of 14,300 tube bundled into 30 stacks, each of which is formed into a chevron shape and separated by spacers and organized into three sectors of 10 nested stacks. The new design replaced metal components with plastic ones, and has a custom built flight like backpressure valve mounted on the side of the SWME housing to reduce backpressure when fully open. The spacers that provided separation of the chevron fiber stacks were eliminated. Vacuum chamber testing showed improved heat rejection as a function of inlet water temperature and water vapor backpressure compared with the previous design. Other tests pushed the limits of tolerance to freezing and showed suitability to reject heat in a Mars pressure environment with and without a sweep gas. Tolerance to contamination by constituents expected to be found in potable water produced by distillation processes was tested in a conventional way by allowing constituents to accumulate in the coolant as evaporation occurs. For this purpose, the SWME cartridge has endured an equivalent of 30 EVAs exposure and demonstrated minimal performance decline.

Bue, Grant↗

NASA NTRS2011

Hollow Fiber Space Water Membrane Evaporator Flight Prototype Design and Testing

The spacesuit water membrane evaporator (SWME) is being developed to perform thermal control for advanced spacesuits and to take advantage of recent advances in micropore membrane technology. This results in a robust heat-rejection device that is potentially less sensitive to contamination than is the sublimator. The current design was based on a previous design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape. This was developed into a full-scale prototype consisting of 14,300 tube bundled into 30 stacks, each of which is formed into a chevron shape and separated by spacers and organized into three sectors of 10 nested stacks. The new design replaced metal components with plastic ones, eliminated the spacers, and has a custom built flight like backpressure valve mounted on the side of the SWME housing to reduce backpressure when fully open. A number of tests were performed in order to improve the strength of the polyurethane header that holds the fibers in place while the system is pressurized. Vacuum chamber testing showed similar heat rejection as a function of inlet water temperature and water vapor backpressure was similar to the previous design. Other tests pushed the limits of tolerance to freezing and showed suitability to reject heat in a Mars pressure environment with and without a sweep gas. Tolerance to contamination by constituents expected to be found in potable water produced by distillation processes was tested in a conventional way by allowing constituents to accumulate in the coolant as evaporation occurs. For this purpose, the SWME cartridge has endured an equivalent of 30 EVAs exposure and demonstrated acceptable performance decline.

Bue, Grant C.↗

DOE OSTI2022

Single-Phase Dielectric Fluid Thermal Management for Power-Dense Automotive Power Electronics

This paper describes the design and performance of a dielectric fluid cooling concept for automotive power electronics. The concept combines a low-thermal-resistance package (which eliminates metalized ceramic substrates) with a high-performance convective cooling strategy (slot jets impinging on finned surfaces). Modeling was first used to design the cooling system to maximize thermal performance and minimize pumping power. Additionally, a prototype was then fabricated, and experiments were conducted to validate the model predictions using three fluids at various fluid flow rates (16.7 cm 3 /s [1 L/min] to 68.3 cm 3 /s [4.1 L/min]) and inlet temperatures (30C and 70C). The final design was compact (120-cm 3 total volume, including heat exchanger and conceptual power modules) and cooled 12 devices (e.g., silicon carbide). The validated model was then used to predict the junction-to-fluid thermal resistance and pumping power for various conditions, including 40C fluid temperature. The results predict thermal resistance values as low as 19 mm 2 K/W are possible using the dielectric fluid cooling approach. The dielectric fluid cooling system is predicted to provide thermal resistance and pumping power values that are approximately 56% and 90% lower, respectively, compared to an automotive power electronics cooling system.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1973

Advanced space engine preliminary design

Analysis and design of an optimum LO2/LH2, combustion topping cycle, 88,964 Newtons (20,000-pound) thrust, liquid rocket engine was conducted. The design selected is well suited to high-energy, upper-stage engine applications such as the Space Tug and embodies features directed toward optimization of vehicle performance. A configuration selection was conducted based on prior Air Force Contracts, and additional criteria for optimum stage performance. Following configuration selection, analyses and design of the major components and engine systems were conducted to sufficient depth to provide layout drawings suitable for subsequent detailing. In addition, engine packaging to a common interface and a retractable nozzle concept were defined. Alternative development plans and related costs were also established. The design embodies high-performance, low-weight, low NPSH requirements (saturated propellant inlet conditions at start), idle-mode operation, and autogenous pressurization. The design is the result of the significant past and current LO2/LH2 technology efforts of the NASA centers and the Air Force, as well as company-funded programs.

Zachary, A. T.↗

NASA NTRS1989

Using an instrumented manikin for Space Station Freedom analysis

One of the most intriguing and complex areas of current computer graphics research is animating human figures to behave in a realistic manner. Believable, accurate human models are desirable for many everyday uses including industrial and architectural design, medical applications, and human factors evaluations. For zero-gravity (0-g) spacecraft design and mission planning scenarios, they are particularly valuable since 0-g conditions are difficult to simulate in a one-gravity Earth environment. At NASA/JSC, an in-house human modeling package called PLAID is currently being used to produce animations for human factors evaluation of Space Station Freedom design issues. Presented here is an introductory background discussion of problems encountered in existing techniques for animating human models and how an instrumented manikin can help improve the realism of these models.

Orr, Linda↗

NASA NTRS1990

Space Station Freedom electric power system photovoltaic power module integrated launch package

The launch of the Space Station Freedom solar power module requires a weight efficient structure that will include large components within the limited load capacity of the Space Shuttle cargo bay. The design iterations to meet these requirements have evolved from a proposal concept featuring a separate cradle and integrated equipment assembly (IEA), to a package that interfaces directly with the Shuttle. Size, weight, and cost have been reduced as a result.

Nathanson, Theodore H.↗

NASA NTRSDate not supplied

Nancy Grace Roman Space Telescope Observatory Implementation and Challenges

NASA’s Nancy Grace Roman Space Telescope (Roman), previously referred to as Wide Field Infrared Survey Telescope (WFIRST), was named after Dr. Nancy Grace Roman, an astronomer and NASA pioneer of modern space-based astronomy who is known as the “mother of the Hubble Space Telescope”. Roman is a deep space infrared observatory with a Hubble-sized telescope and wide field of view instrument (greater than 100 times that of Hubble’s) that will conduct a high latitude time-domain survey, a high latitude imaging and spectroscopic survey, and a galactic bulge time-domain survey to characterize dark energy and expand the census of exoplanets in our galaxy while allowing a broad range of astrophysics research. Roman will also demonstrate exoplanet coronagraphy with active wave front control technology and provide general investigator programs for the science community. Roman is finishing the critical design phase and is planning for launch in 2026. It will operate in a quasi-halo orbit about Sun-Earth L2, 1.5 million kilometers from Earth, for a five-year primary mission life. The Observatory features an Optical Telescope Assembly with an existing, repurposed 2.4m primary mirror, a Wide Field Instrument with a focal plane array comprised of 18 HgCdTe near-infrared detectors and a grism, prism and filter elements for imaging and spectroscopy in support of the primary surveys, as well as a Coronagraph instrument technology demonstration with starlight suppression technology for direct imaging and spectroscopy of exoplanets. The telescope is mounted to the Instrument Carrier composite truss structure which also optically meters each instrument, includes a Launch Load and Vibration Isolation System to provide passive isolation of spacecraft jitter sources while also supporting the payload during launch and is attached to the Spacecraft Bus. The Spacecraft also includes a Solar Array Sunshield ,Deployable Aperture Cover, Lower Instrument Sunshade, High Gain Antenna System, and Outer Barrel Assembly. Figure 1 shows an overview of the Roman Observatory. When fully integrated, Roman will be the largest Observatory assembled and tested at NASA’s Goddard Space Flight Center. Figure 1. Roman Observatory Overview Development of scientific satellites is challenging by nature, as the pursuit to broaden scientific knowledge always pushes the boundary of what has come before. The implementation of the Roman mission is a prime example and expected challenges have been augmented by the foundational decision to use the existing telescope components, developed in the early 2000s by another Government agency for a different application. Other unique aspects of the Roman mission, such as its survey nature, the vast amount of data required to meet science objectives, and packaging of the Observatory elements around the existing telescope components, create constrained design spaces that drive competing requirements across Observatory subsystems. Given these challenges, systems engineering has been a critical discipline in balancing implementation decisions for the Roman mission and will continue to play a key role going forward. This paper will discuss details of the Roman Observatory configuration, as well as some of the systems engineering challenges and the decision-making process used to mature the Roman Space Telescope preliminary design to implementation.

Lisa Ml Bartusek↗

NASA NTRS2000

Hydrogen Sensors Demonstrated on the Shuttle

Microelectromechanical-systems- (MEMS-) based hydrogen sensor technology developed by the NASA Glenn Research Center at Lewis Field and Case Western Reserve University was demonstrated on shuttle missions STS-95 (Senator Glenn s mission) and STS-96. These smart sensors, commercialized by Makel Engineering Inc., were part of an "Integrated Vehicle Health Monitoring HEDS Technology Demonstration" series conducted at the NASA Kennedy Space Center. The experiments were designed to demonstrate the effect of technological upgrades on shuttle performance. The hydrogen sensors were micro-fabricated for minimal size, weight, and power consumption. A temperature detector and heater were included on the sensor for temperature control. Two palladium chrome (PdCr) hydrogen detection devices were included in each sensor package: a Schottky diode for low concentrations and a resistor for high concentrations. These sensor designs allow operation in inert environments. "Smart" electronics developed by Makel Engineering were integrated with the sensors to control the sensor temperature and process the output of the various sensors. This complete hydrogen detection system (two sensors on a chip with smart electronics) flew on STS-95 (launched October 1998) and STS-96 (launched May 1999). It was installed in the aft compartment of the shuttle and used to monitor the hydrogen concentration in that region. Up to this time, a mass spectrometer had monitored the hydrogen concentration in the aft compartment before launch, and "grab" bottles had been used after launch. The inside of these bottles is at vacuum. During flight, the grab bottles are pyrotechnically opened for a brief period, and the gas in the aft compartment is captured in the bottle. Several of these bottles are opened at different times during takeoff, and their contents are used to determine the time profile of the gases in the aft chamber. However, this information is not available until after the flight. On the launch pad, results from the new sensor technology paralleled the responses of the mass spectrometer with, in some cases, a quicker response time. In flight, data from the new sensors agreed with those derived from analyzing the contents of the grab bottles. Moreover, this microsensor can monitor the aft compartment continuously and, in principle, could monitor the health of the vehicle in real time during flight.

Hunter, Gary W.↗

DOE OSTI2022

Utilization of the LMP Methodology in Support of the VTR Conceptual Safety Design Report

The Versatile Test Reactor (VTR) is a fast spectrum test reactor currently being developed in the United States under the direction of the US Department of Energy (DOE), Office of Nuclear Energy. The VTR is utilizing a risk-informed performance-based (RIPB) approach for design support and authorization by the DOE, derived from recent efforts by the US industry led Licensing Modernization Project (LMP). This document contains an overview of the implementation of the LMP approach in support of the VTR Conceptual Safety Design Report (CSDR). The work reported here is the result of studies supporting a VTR conceptual design, cost, and schedule estimate for DOE-NE to make a decision on procurement. As such, it is preliminary. The VTR RIPB authorization approach utilizes information from the probabilistic risk assessment (PRA), coupled with deterministic analyses, to aid in decision-making regarding the identification and categorization of safety basis events (SBEs), the classification of structures, systems, and components (SSCs), and the evaluation of defense-in-depth (DID) adequacy. As part of initial reactor design efforts, a VTR conceptual design PRA was developed to support the RIPB process, which focused on at-power internal events, with scoping analyses for seismic and sodium fire hazards. In addition to supporting numerous design studies, preliminary results from the RIPB approach and the VTR conceptual design PRA were utilized as the basis of the VTR CSDR. The initial identification and categorization of SBEs, SSC classification, and DID evaluation were contained within the CSDR, which was submitted to DOE in 2019 as part of the CD-1 submittal package. Following review, DOE approved the CSDR in April 2020 and the CD-1 package in late 2020. Valuable experience was gained through the implementation of the RIPB approach for design and authorization during the VTR conceptual design phase, which is summarized in this document. To the extent possible, this experience has been shared with the advanced reactor industry, through publications and participation in licensing tabletops, in addition to informing DOE:NE advanced reactor regulatory development efforts. Furthermore, the approval of the CSDR by the DOE as part of CD-1 represents a significant milestone in the use of RIPB approaches for advanced reactor licensing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗