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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↗

NASA NTRS1974

Investigation of application of two-degree-of-freedom dry tuned-gimbal gyroscopes to strapdown navigation systems

The work is described which was accomplished during the investigation of the application of dry-tuned gimbal gyroscopes to strapdown navigation systems. A conventional strapdown configuration, employing analog electronics in conjunction with digital attitude and navigation computation, was examined using various levels of redundancy and both orthogonal and nonorthogonal sensor orientations. It is concluded that the cost and reliability performance constraints which had been established could not be met simultaneously with such a system. This conclusion led to the examination of an alternative system configuration which utilizes an essentially new strapdown system concept. This system employs all-digital signal processing in conjunction with the newly-developed large scale integration (LSI) electronic packaging techniques and a new two-degree-of-freedom dry tuned-gimbal instrument which is capable of providing both angular rate and acceleration information. Such a system is capable of exceeding the established performance goals.

Source record↗

NASA NTRS1987

Stability studies of Solar Optical Telescope dynamics

The Solar Optical Telescope (SOT) is designed to operate as an attached payload mounted on the Instrument Pointing System (IPS) in the cargo bay of the Shuttle Orbiter. Pointing and control of SOT is accomplished by an active Articulated Primary Mirror (APM), an active Tertiary Mirror (TM), an elaborate set of optical sensors, electromechanical actuators and programmable controllers. The structural interactions of this complex control system are significant factors in the stability of the SOT. The preliminary stability study results of the SOT dynamical system are presented. Structural transfer functions obtained from the NASTRAN model of the structure were used. These studies apply to a single degree of freedom (elevation). Fully integrated model studies will be conducted in the future.

Gullapalli, Sarma N.↗

NASA NTRS1990

Cockpit display of hazardous wind shear information

Information on cockpit display of wind shear information is given in viewgraph form. Based on the current status of windshear sensors and candidate data dissemination systems, the near-term capabilities for windshear avoidance will most likely include: (1) Ground-based detection: TDWR (Terminal Doppler Weather Radar), LLWAS (Low-Level Windshear Alert System), Automated PIREPS; (2) Ground-Air datalinks: Air traffic control voice channels, Mode-S digital datalink, ACARS alphanumeric datalink. The possible datapaths for integration of these systems are illustrated in a diagram. In the future, airborne windshear detection systems such as lidars, passive IR detectors, or airborne Doppler radars may also become available. Possible future datalinks include satellite downlink and specialized en route weather channels.

Wanke, Craig↗

NASA NTRS2000

IVHM for the 3rd Generation RLV Program: Technology Development

The objective behind the Integrated Vehicle Health Management (IVHM) project is to develop and integrate the technologies which can provide a continuous, intelligent, and adaptive health state of a vehicle and use this information to improve safety and reduce costs of operations. Technological areas discussed include: developing, validating, and transfering next generation IVHM technologies to near term industry and government reusable launch systems; focus NASA on the next generation and highly advanced sensor and software technologies; and validating IVHM systems engineering design process for future programs.

Kahle, Bill↗

NASA NTRS2011

Miniature, Low-Power, Waveguide Based Infrared Fourier Transform Spectrometer for Spacecraft Remote Sensing

Fourier transform spectrometers have a venerable heritage as flight instruments. However, obtaining an accurate spectrum exacts a penalty in instrument mass and power requirements. Recent advances in a broad class of non-scanning Fourier transform spectrometer (FTS) devices, generally called spatial heterodyne spectrometers, offer distinct advantages as flight optimized systems. We are developing a miniaturized system that employs photonics lightwave circuit principles and functions as an FTS operating in the 7-14 micrometer spectral region. The inteferogram is constructed from an ensemble of Mach-Zehnder interferometers with path length differences calibrated to mimic scan mirror sample positions of a classic Michelson type FTS. One potential long-term application of this technology in low cost planetary missions is the concept of a self-contained sensor system. We are developing a systems architecture concept for wide area in situ and remote monitoring of characteristic properties that are of scientific interest. The system will be based on wavelength- and resolution-independent spectroscopic sensors for studying atmospheric and surface chemistry, physics, and mineralogy. The self-contained sensor network is based on our concept of an Addressable Photonics Cube (APC) which has real-time flexibility and broad science applications. It is envisaged that a spatially distributed autonomous sensor web concept that integrates multiple APCs will be reactive and dynamically driven. The network is designed to respond in an event- or model-driven manner or reconfigured as needed.

Hewagama, TIlak↗

NASA NTRS2015

Fabrication of Feedhorn-Coupled Transition Edge Sensor Arrays for Measurement of the Cosmic Microwave Background Polarization

Characterization of the minute cosmic microwave background (CMB) polarization signature requires multi-frequency high-throughput precision instrument systems. We have previously described the detector fabrication of a 40 gigahertz focal plane and now describe the fabrication of a 37-element dual-polarization detector module for measurement of the CMB at 90 gigahertz. The 72-TES (Transition Edge Sensor)-based bolometers in each module are coupled to a niobium-based planar orthomode transducer with integrated band defining filters implemented in microstrip transmission line. A single crystal silicon dielectric substrate serves as microstrip dielectric and as a thermal link between the membrane isolated MoAu TES operating at 150 millikelvins and the heat bath. A short silicon leg between the heat bath and the TES bolometer is designed for ballistic phonon transport and provides improved process control and uniformity of thermal conductance in the presence of phonon scattering on roughened surfaces. Micro-machined structures are used to realize the orthomode transducer backshort, provide out of band signal rejection, and a silicon photonic choke for feedhorn coupling are described. The backshort, choke wafer, and detector wafer are indium bump-bonded to create a single 37-element dual-polarization detector module. Fourteen such hexagonally shaped modules each 80 millimeters in size comprise two focal planes. These, along with the recently delivered 40 gigahertz focal plane, will survey a large fraction of the sky as part of the Johns Hopkins University-led ground-based CLASS (Cosmology Large Angular Scale Surveyor) telescope.

Detectors↗

NASA NTRS2016

Use of a Small Unmanned Aircraft System for Autonomous Fire Spotting at the Great Dismal Swamp

This paper describes the results of a set of experiments and analyses conducted to evaluate the capability of small unmanned aircraft systems (sUAS) to spot nascent fires in the Great Dismal Swamp (GDS) National Wildlife Refuge. This work is the result of a partnership between the National Aeronautics and Space Administration and the US Fish and Wildlife service specifically to investigate sUAS usage for fire-spotting. The objectives of the current effort were to: 1) Determine suitability and utility of low-cost Small Unmanned Aircraft Systems (sUAS) to detect nascent fires at GDS; 2) Identify and assess the necessary National Airspace System (NAS) integration issues; and 3) Provide information to GDS and the community on system requirements and concepts-of-operation (CONOPS) for conducting fire detection/support mission in the National Airspace and (4) Identify potential applications of intelligent autonomy that would enable or benefit this high-value mission. In addition, data on the ability of various low-cost sensors to detect smoke plumes and fire hot spots was generated during the experiments as well as identifying a path towards a future practical mission utility by using sUAS in beyond visual-line-of-sight operation in the National Airspace System (NAS).

Logan, Michael J.↗

NASA NTRSDate not supplied

NASA's New Wildland Fire Earth Observation Science & Applications Programmatic Developments

In 2021, the U.S. National Aeronautics & Space Administration (NASA) initiated new programmatic elements within the Science Mission Directorate (SMD) and the Aeronautics Research Mission Directorate (ARMD) focused on supporting wildland fire science and applications improvements, employing the vast array of NASA scientific knowledge, airborne and space-borne Earth Observations (EO) capabilities, technology development (sensor systems, etc.), and large framework modeling efforts. Within the Science Mission Directorate, the NASA Earth Science Division (ESD) will focus on improving our understanding of wildland fire through EO tools and applying rigorous-tested modeling and results of that research into operational use. The ESD Wildfire strategy is to invest in new technology and to better integrate NASA’s satellite, airborne, and ground-based observations with wildfire models to provide the wildfire stakeholders with the information they need to make informed decisions about the pre-, active-, and post-fire conditions. The Applied Science Program has restarted the Wildland Fire Applications Program with a focus on engaging wildland fire management and the fire science community in transitioning EO science efforts into routine use by land management entities at the local, state, national and international level. The NASA Aeronautics Research Mission Directorate will focus on arenas where their aeronautics science and engineering outcomes can benefit the fire management community as well, specifically in the innovative development of Uncrewed Aircraft systems, congested mixed-use platform airspace management issues, new platform configurations supporting wildland fire missions, and other aeronautics-related science / engineering capabilities which may benefit the fire management community. In total, these developments represent a major thrust forward, supporting the goals of utilizing NASA science to benefit humankind. This presentation will highlight the various wildland fire science focus areas identified through collaborations with the wildland fire science and management community and highlight the plans of this new NASA focus area.

NASA↗

NASA NTRS2005

Algorithm Science to Operations for the National Polar-orbiting Operational Environmental Satellite System (NPOESS) Visible/Infrared Imager/Radiometer Suite (VIIRS)

The VIIRS sensor provides measurements for 22 Environmental Data Records (EDRs) addressing the atmosphere, ocean surface temperature, ocean color, land parameters, aerosols, imaging for clouds and ice, and more. That is, the VIIRS collects visible and infrared radiometric data of the Earth's atmosphere, ocean, and land surfaces. Data types include atmospheric, clouds, Earth radiation budget, land/water and sea surface temperature, ocean color, and low light imagery. This wide scope of measurements calls for the preparation of a multiplicity of Algorithm Theoretical Basis Documents (ATBDs), and, additionally, for intermediate products such as cloud mask, et al. Furthermore, the VIIRS interacts with three or more other sensors. This paper addresses selected and crucial elements of the process being used to convert and test an immense volume of a maturing and changing science code to the initial operational source code in preparation for launch of NPP. The integrity of the original science code is maintained and enhanced via baseline comparisons when re-hosted, in addition to multiple planned code performance reviews.

NPOESS (NATIONAL POLAR-ORBITING OPERATIONAL ENVIRO↗

NASA NTRS2022

Development of an End-to-end Demonstration Readout Chain for Athena/X-IFU

The X-ray Integral Field Unit(X-IFU) of the Athena observatory, scheduled for launch in the mid2030's, will provide X-ray spectroscopy data with unprecedented spectral and spatial resolution. This will be achieved with a 2kilo-pixel array of transition-edge sensor (TES) microcalorimeters. The complete detection chain is under development by a large international collaboration. In order to perform an end-to-end demonstration of the X-IFU readout chain, a 50 mK test bench is being developed at IRAP in collaboration with CNES. The test bench uses a two-stage ADR cryostat from Entropy GmbH, a 1024-pixelarray, and will initially be operated using a warm electronics chain from NIST and NASA Goddard Space Flight Center. We describe the complete system being installed in the cryostat and the current results obtained with these electronics. We also review the status of the integration of the digital readout electronics (DRE)prototype into the demonstration chain and the plan for integrating and testing the complete X-IFU readout chain.

S Beaumont↗

NASA NTRS2000

The Life Cycle Application of Intelligent Software Modeling for the First Materials Science Research Rack

Marshall Space Flight Center (MSFC) has been funding development of intelligent software models to benefit payload ground operations for nearly a decade. Experience gained from simulator development and real-time monitoring and control is being applied to engineering design, testing, and operation of the First Material Science Research Rack (MSRR-1). MSRR-1 is the first rack in a suite of three racks comprising the Materials Science Research Facility (MSRF) which will operate on the International Space Station (ISS). The MSRF will accommodate advanced microgravity investigations in areas such as the fields of solidification of metals and alloys, thermo-physical properties of polymers, crystal growth studies of semiconductor materials, and research in ceramics and glasses. The MSRR-1 is a joint venture between NASA and the European Space Agency (ESA) to study the behavior of different materials during high temperature processing in a low gravity environment. The planned MSRR-1 mission duration is five (5) years on-orbit and the total design life is ten (IO) years. The MSRR-1 launch is scheduled on the third Utilization Flight (UF-3) to ISS, currently in February of 2003). The objective of MSRR-1 is to provide an early capability on the ISS to conduct material science, materials technology, and space product research investigations in microgravity. It will provide a modular, multi-user facility for microgravity research in materials crystal growth and solidification. An intelligent software model of MSRR-1 is under development and will serve multiple purposes to support the engineering analysis, testing, training, and operational phases of the MSRR-1 life cycle development. The G2 real-time expert system software environment developed by Gensym Corporation was selected as the intelligent system shell for this development work based on past experience gained and the effectiveness of the programming environment. Our approach of multi- uses of the simulation model and its intuitive graphics capabilities is providing a concurrent engineering environment for rapid prototyping and development. Operational schematics of the MSRR-1 electrical, thermal control, vacuum access, and gas supply systems, and furnace inserts are represented graphically in the environment. Logic to represent first order engineering calculations is coded into the knowledge base to simulate the operational behavior of the MSRR-1 systems. An example of engineering data provided includes electrical currents, voltages, operational power, temperatures, thermal fluid flow rates. pressures, and component status indications. These type of data are calculated and displayed at appropriate instrumentation points, and the schematics are animated to reflect the simulated operational status of the MSRR-1. The software control functions are also simulated to represent appropriate operational behavior based on automated control and response to commands received by the crew or ground controllers. The first benefit of this simulation environment is being realized in the high fidelity engineering analysis results from the electrical power system G2 model. Secondly, the MSRR-1 simulation model will be embedded with a hardware mock-up of the MSRR-1 to provide crew training on MSRR-1 integrated payload operations. G2 gateway code will output the simulated instrumentation values, termed as telemetry, in a flight-like data stream so that the crew has realistic and accurate simulated MSRR-1 data on the flight displays which will be designed for crew use. The simulation will also respond appropriately to crew or ground initiated commands, which will be part of normal facility operations. A third use of the G2 model is being planned; the MSRR-1 simulation will be integrated with additional software code as part of the test configuration of the primary onboard computer, or Master Controller, for MSRR-1. We will take advantage of the G2 capability to simulate the flight like data stream to test flight software responses and behavior. A fourth use of the G2 model will be to train the Ground Support Personnel that will monitor the MSRR-1 systems and payloads while they are operating aboard the ISS. The intuitive, schematic based environment will provide an excellent foundation for personnel to understand the integrated configuration and operation of the MSRR-1, and the anticipated telemetry feedback based on operational modes of the equipment. Expert monitoring features will be enhanced to provide a smart monitoring environment for the operators. These features include: (1) Animated, intuitive schematic-based displays which reflect telemetry values, (1) Real-time plotting of simulated or incoming sensor values, (3) High/Low exception monitoring for analog data, (4) Expected state monitoring for discrete data, (5) Data trending, (6) Automated malfunction procedure execution to diagnose problems, (7) Look ahead capability to planned MSRR-1 activities in the onboard timeline. And finally, the logic to calculate telemetry values will be deactivated, and the same environment will interface to the incoming data for the real-time telemetry stream to schematically represent the onboard hardware configuration. G2 will be the foundation for the real-time monitoring and control environment. In summary, our MSRR-1 simulation model spans many elements of the life cycle development of this project: Engineering Analysis, Test and Checkout, Training of Crew and Ground Personnel, and Real-time monitoring and control. By utilizing the unique features afforded by an expert system development environment, we have been able to synergize a powerful tool capable of addressing our project needs at every phase of project development.

Rice, Amanda↗

DOE OSTI2022

A SiPM-based optical readout system for the EIC dual-radiator RICH

Silicon photomultipliers (SiPM) are candidates selected as the potential photodetector technology for the dual-radiator Ring-Imaging Cherenkov (dRICH) detector at the future Electron-Ion Collider (EIC). SiPM are cheap devices, highly efficient and insensitive to the high magnetic field at the expected location of the sensors in the experiment. Here, on the other hand, SiPM are not radiation tolerant. Despite the integrated radiation level is expected to be moderate it should be tested whether single photon-counting capabilities and the increase in dark count rate can be kept under control to maintain the optimal dRICH detector performance across the years. The current status of the research for the EIC dRICH application and the first results on studies performed on a sample of commercial and prototype SiPM sensors are presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2004

Medusa Sea Floor Monitoring System

The objective of the research described in this poster presentation is to develop technologies to enable fundamental research into understanding the potential for and limits to chemolithoautotrophic life. The Medusa Isosampler (isobaric sampler), for sampling fluids eminating from deep sea hydrothermal vents and cold seep sites analogous to extraterrestrial environments, is described by the presentation. The following instruments are integrated with the isosampler, and also described: in situ flow-through chemical sensor, intrinsic fluorescent-based microbial detector, isotope ratio spectral detector.

Flynn, Michael↗

DOE OSTI2022

Smart connected worker edge platform for smart manufacturing: Part 1—Architecture and platform design

Abstract The challenge of sustainably producing goods and services for healthy living on a healthy planet requires simultaneous consideration of economic, societal, and environmental dimensions in manufacturing. Enabling technology for data driven manufacturing paradigms like Smart Manufacturing (a.k.a. Industry 4.0) serve as the technological backbone from which sustainable approaches to manufacturing can be implemented. Unfortunately, these technologies are typically associated with broader and deeper factory automation that is often too expensive and complex for the small and medium sized manufacturers (SMMs) that comprise the majority of manufacturing business in the USA and for whom their most valuable asset are the people whose jobs automation while replace. This paper describes an edge intelligent platform to integrate internet‐of‐things technologies with computing hardware, software, computational workflows for machine learning, and data ingestion, enabling SMMs to transition into smart manufacturing paradigms by leveraging the intelligence of their people. The platform leverages consumer grade electronics and sensors (affordable and portable), customized software with open source software packages (accessible), and existing communication network infrastructures (scalable). The software systems are implemented via Kubernetes orchestration of Docker containerization to ensure scalability and programmability. The platform is adaptive via computational workflow engines that produce information from data by processing with low‐cost edge computing devices while efficiently accessing resources of cloud servers as needed. The proposed edge platform connects workers to technological resources that provide computational intelligence (i.e., silicon‐based sensing and computation for data collection and contextualization) to enable decision making at the edge of advanced manufacturing.

Kim, Yoon G.↗

DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗

DOE OSTI2026

Two 28-nm front-end ASICs for ultra-fine spatial resolution and precision timing to be 3D integrated with 12 LGADs

The 3DIntSenS Collaboration—a joint effort between SLAC, Fermilab, and LLNL—is developing enabling technologies for next-generation radiation imaging detectors that combine ultra-fine spatial resolution (about 10 µm) with precision timing (<20 ps), while maintaining low power <1 W/cm2 and high data throughput. The approach leverages 3D integration between advanced CMOS readout ASICs and finely pixelated LGAD sensors to achieve the performance and scalability required for large-area, high-rate applications. High-granularity, precision-timing detectors are essential for scientific advances in HEP, NP, BES, and FES, but widespread adoption is limited by the cost and complexity of 3D integration. To close this gap, the collaboration is developing LGAD sensors compatible with 12-inch commercial CMOS processes, enabling cost-effective integration with high-performance ASICs under development. We present two 28 nm CMOS ASIC prototypes, including a low-jitter front end, and in-pixel TDC demonstrating sub-10 ps timing resolution. These advances represent a critical step toward scalable, high-resolution radiation imaging systems for future scientific instrumentation.

England, Troy [Fermilab] (ORCID:0000000154405255)↗

DOE OSTI2026

Two 28-nm front-end ASICs for ultra-fine spatial resolution and precision timing to be 3D integrated with 12 LGADs

England, Troy [Fermilab] (ORCID:0000000154405255)↗