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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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Design and Testing of a Hard-Fault Protection Circuit for a 1 kV SiC MOSFET Inverter

Due to increasingly high DC link voltages and further advancements in the current density of silicon carbide (SiC) MOSFETs, it has become evident that conventional IGBT protection methods are not sufficient to prevent exceeding the current rating of these devices during low-inductance fault events. This paper explores the use of an air core Rogowski coil topology to mitigate these hard fault events. The design of this circuit resulted in safe shutdown of a low impedance phase-to-phase fault in under one microsecond, tested up to DC link voltages of 1 kV. This paper details the theory, design, simulation, and successful test results of this method.

hard fault protection↗

NASA's X-57 High Lift Motor Controller: Detailed Design, Test Results, and Outcomes

NASA's X-57 all-electric aircraft was a research project aimed at investigating lightweight and efficient electric propulsion components. The general approach was to utilize a distributed electric propulsion (DEP) design. An essential component of this design was the High Lift Motor Controller (HLMC), a motor drive which provided power to the High Lift Motors (HLMs) and High Lift Propellers (HLPs) responsible for providing additional thrust for take-off and landing. This paper presents the detailed design, test results, and outcomes from the development of the HLMC, a 14 kW, 1kg, 98.3% efficient, outer mold line (OML) cooled, silicon carbide (SiC) MOSFET-based inverter and controller.

Electric Aircraft↗

NASA's X-57 High Lift Motor Controller: Detailed Design, Test Results, and Outcomes

NASA's X-57 all-electric aircraft was a research project aimed at investigating lightweight and efficient electric propulsion components. The general approach was to utilize a distributed electric propulsion (DEP) design. An essential component of this design was the High Lift Motor Controller (HLMC), a motor drive which provided power to the High Lift Motors (HLMs) and High Lift Propellers (HLPs) responsible for providing additional thrust for take-off and landing. This paper presents the detailed design, test results, and outcomes from the development of the HLMC, a 14 kW, 1kg, 98.3% efficient, outer mold line (OML) cooled, silicon carbide (SiC) MOSFET-based inverter and controller.

Electric Aircraft↗

N channel JFET based digital logic gate structure

A circuit topography is presented which is used to create usable digital logic gates using N (negatively doped) channel Junction Field Effect Transistors (JFETs) and load resistors, level shifting resistors, and supply rails whose values are based on the direct current (DC) parametric distributions of those JFETs. This method has direct application to the current state of the art in high temperature, for example 300.degree. C. to 500.degree. C. and higher, silicon carbide (SiC) device production. The ability to produce inverting and combinatorial logic enables the production of pulse and edge triggered latches. This scale of logic synthesis would bring digital logic and state machine capabilities to devices operating in extremely hot environments, such as the surface of Venus, near hydrothermal vents, within nuclear reactors (SiC is inherently radiation hardened), and within internal combustion engines. The basic logic gate can be configured as a driver for oscillator circuits allowing for time bases and simple digitizers for resistive or reactive sensors. The basic structure of this innovation, the inverter, can be reconfigured into various analog circuit topographies through the use of feedback structures.

Krasowski, Michael J.↗

CarbAl Heat Transfer Material

The increasing use of power electronics, such as high-current semiconductor devices and modules, within space vehicles is driving the need to develop specialty thermal management materials in both the packaging of these discrete devices and the packaging of modules consisting of these device arrays. Developed by Applied Nanotech, Inc. (ANI), CarbAl heat transfer material is uniquely characterized by its low density, high thermal diffusivity, and high thermal conductivity. Its coefficient of thermal expansion (CTE) is similar to most power electronic materials, making it an effective base plate substrate for state-of-the-art silicon carbide (SiC) super junction transistors. The material currently is being used to optimize hybrid vehicle inverter packaging. Adapting CarbAl-based substrates to space applications was a major focus of the SBIR project work. In Phase I, ANI completed modeling and experimentation to validate its deployment in a space environment. Key parameters related to cryogenic temperature scaling of CTE, thermal conductivity, and mechanical strength. In Phase II, the company concentrated on improving heat sinks and thermally conductive circuit boards for power electronic applications.

Fink, Richard↗

Development and evaluation of die materials for use in the growth of silicon ribbons by the inverted ribbon growth process, task 2, LSSA project

Silicon sessile drop experiments were performed on a variety of commercially available refractory carbides, nitrides, oxides, and borides to examine the potential of these materials for applications involving either direct contact with molten silicon or as substrates for CVD coatings in the fabrication of dies and crucibles for containing molten silicon. Simultaneous experiments were also conducted with CVD layers of SiC, Si3N4, and SiOxNy. Silicon nitride layers, deposited with NH3:SiH4 ratios ranging from 100:1 down to 5:1, were examined in sessile drop experiments to determine if the layers are degraded as a result of using lower reagent ratios. Preliminary experiments were undertaken on the stability of CVD Si3N4 near the melting point of silicon. Silicon ribbon segments were grown from vitreous carbon dies which had been coated with CVD Si3N4. Depending upon the purity of the die materials, ribbon resistivity values up to 40 Omega cm were obtained.

Duffy, M. T.↗

Measurement of interfacial shear strength in SiC-fiber/Si3N4 composites

An indentation method for measuring shear strength in brittle matrix composites was applied to SiC-fiber/Si3N4-matrix samples. Three methods were used to manufacture the composites: reaction bonding of a Si/SiC preform, hot-pressing, and nitrogen-overpressure sintering. An indentation technique developed by Marshall for thin specimens was used to measure the shear strength of the interface and the interfacial friction stresses. This was done by inverting the sample after the initial push through and retesting the pushed fibers. SEM observations showed that the shear strength was determined by the degree of reaction between the fiber and the matrix unless the fiber was pushed out of its (well-bonded) sheath.

Laughner, James W.↗

X-57 Electromagnetic Interference Design, Integration, and Test Consideration

X-57 is NASA’s first all electric aircraft that utilizes existing airframe of Tecnam 2006P GA aircraft integrated with new all electric power train. The objective of the project was to deliver high performing distributed electric propulsion system while developing US industry in the area of EAP. The project was divided into three distinct flight mods, each serving as a risk reduction efforts to final mod where full distributed power train with highly modified wing structure would be tested in flight. Flight weight, efficient power electronics are enablers for distributed, electric aircraft propulsion systems, and GRC team has developed high power and highly efficient SiC based converters for both cruise and high lift systems on the aircraft. Both controller’s development efforts demonstrate a means to achieve an in-the-nacelle controller with purely passive cooling while maintaining high efficiency. This paper describes the lessons learned on design, integration, and testing challenges that X-57 faced while developing these novel technologies.

Power Train↗