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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Exploring the Limits of Cooling for Extreme Heat Flux Applications: Data Centers and Power Electronic

We developed an Extreme Heat Flux Micro-cooler (EHFµ-C) capable of removing heat flux of ~1 kW/cm 2 with a small temperature rise ~10°C. This represents greater than 10× reduction in thermal resistance compared to the state-of-the-art single-phase cooling technologies (~0.5 cm 2 -°C/W) that greatly increases the efficiency, resulting in improved performance and reliability for microprocessors and power electronics. The EHFµ-Cooler utilizes liquid wicking (no pump) and thin-film evaporation in a 30 µm thick wick porous microstructure such as copper inverse opal (CIO), silicon and AlN pin fins along with a 3D manifold (copper wiremesh and silicon) with liquid routing and vapor extraction channels achieving an unprecedented vapor quality ~ >0.9. The proposed EHFµ-Cooler significantly reduces device temperature, resulting in 25-50% improvement in reliability and device performance. Based on very conservative estimates, the total energy saving for data centers due to improved performance can be 6 billion kWh/year (>$300M). Better cooling, leading to more efficient, higher performance and more reliable power electronics, would save the nation 3 Quad of primary energy in 2030. Just for automotive application, a 10% increase in fuel efficiency for SiC-based power electronics equates to >20 million gallons of fuel savings annually. The proposed EHFµ-Cooler technology ensures the United States maintains its technological lead in high-performance computing and high-power electronics, while at the same time improving the energy efficiency, and as a result reducing energy-related emissions such as greenhouse gases.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2010

NASA Electronic Parts and Packaging (NEPP) Program - Update

This slide presentation reviews the goals and mission of the NASA Electronic Parts and Packaging (NEPP) Program. The NEPP mission is to provide guidance to NASA for the selection and application of microelectronics technologies, to improve understanding of the risks related to the use of these technologies in the space environment and to ensure that appropriate research is performed to meet NASA mission assurance needs. The program has been supporting NASA for over 20 years. The focus is on the reliability aspects of electronic devices. In this work the program also supports the electronics industry. There are several areas that the program is involved in: Memories, systems on a chip (SOCs), data conversion devices, power MOSFETS, power converters, scaled CMOS, capacitors, linear devices, fiber optics, and other electronics such as sensors, cryogenic and SiGe that are used in space systems. Each of these area are reviewed with the work that is being done in reliability and effects of radiation on these technologies.

LaBel, Kenneth A.↗
DOE OSTI2022

Ultra High-Temperature Magnetic Bearing System for s-CO 2 Turbines/Expanders. Phase II Final Report

The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS2015

NASA Manufacturing and Test Requirements for Normally Closed Pyrovalves for Hazardous Flight Systems Applications

Pyrovalves (figure 1, Basic Pyrovalve Design and Features,) are typically lighter, more reliable, and in most cases less expensive than other types of valves. They also consume less electrical power. They are single-use devices that are used in propulsion systems to isolate propellants or pressurant gases. These fluids may be hazardous because of their toxicity, reactivity, temperature, or high pressure. Note that in the simplified block diagram below not all detail features are shown so that those of major interest are more prominent. The diagram is provided to point out the various features that are discussed in this Specification. Features of some NC parent metal valve designs may differ. In 2013, the NESC concluded an extensive study of the reliability and safety of NC parent metal valves used in payloads carried aboard ELVs. The assessment successfully evaluated technical data to determine the risk of NC parent metal valve leakage or inadvertent activation in ELV payloads. The study resulted in numerous recommendations to ensure personnel and hardware/facility safety during ground processing of ELV payloads. One of those recommendations was to establish a NASA specification for NC parent metal valves. This Specification is a result of that recommendation, which is documented in NESC-RP-10-00614.

McDougle, Stephen H.↗
NASA NTRS2012

Reliability Considerations for Ultra- Low Power Space Applications

NASA, the aerospace community, and other high reliability (hi-rel) users of advanced microelectronic products face many challenges as technology continues to scale into the deep sub- micron region and ULP devices are sought after. Technology trends, ULP microelectronics, scaling and performance tradeoffs, reliability considerations, and spacecraft environments will be presented from a ULP perspective for space applications.

reliability↗
DOE OSTI2022

Thermoelectric coolers for high-power-density 3D electronics heat management

Future advancements in three-dimensional (3D) electronics require robust thermal management methodology. Thermoelectric coolers (TECs) are reliable and solid-state heat pumping devices with high cooling capacity that can meet the requirements of emerging 3D microelectronic devices. In this work, we first provide the design of TECs for electronics cooling using a computational model and then experimentally validate the main predictions. Key device parameters such as device thickness, leg density, and contact resistance were studied to understand their influence on the performance of TECs. Our results show that it is possible to achieve high cooling power density through optimization of TE leg height and packing density. Scaling of TECs is shown to provide ultra-high cooling power density.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Switchable Charge Storage Mechanism via in Situ Activation of MXene Enables High Capacitance and Stability in Aqueous Electrolytes

The need for reliable renewable energy storage devices has become increasingly important. However, the performance of current electrochemical energy storage devices is limited by either low energy or power densities and short lifespans. Herein, we report the synthesis and characterization of multilayer Ti 4 N 3 T x MXene in various aqueous electrolytes. We demonstrate that Ti 4 N 3 T x can be electrochemically activated through continuous cation intercalation over a 10 day period using cyclic voltammetry. A wide operating window of 2 V is maintained throughout activation. After activation, capacitance at 2 mV s -1 increases by 300%, 140%, and 500% in 1 M H2SO4, 1 M MgSO4, and 1 M KOH, respectively, while maintaining ~600 F g -1 at 2 mV s–1 after 50000 cycles in 1 M H 2 SO 4 . This activation process is possibly attributed to the unique morphology of the multilayered material, allowing cation intercalation to increase access to redox-active sites between layers. This work adds to the growing repository of electrochemically stable MXenes reported for aqueous energy storage applications. These findings offer a reliable option for reliable energy storage devices with potential applications in large-scale grid storage and electric vehicles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

A proposed high-intensity radiometer calibration method using concentrated solar radiation

Accurate calibration of irradiance measurement devices, or radiometers, is essential for ensuring the reliability of measurements in high heat applications such as concentrating solar power (CSP), aerospace, defense, and pulsed power systems. Despite the critical need, existing calibration standards and service providers are limited to irradiance levels below 100 kW/m 2 and specific radiation sources, which is insufficient for many applications. For instance, CSP technologies, particularly those under the Department of Energy’s Solar Energy Technologies Office (SETO) Gen 3 program, require accurate measurements of broadband irradiance at levels exceeding 2000 kW/m 2 . In even more extreme scenarios, such as re-entry vehicles, heat levels can surpass 10000 kW/m 2 . Current ISO standards, specifically ISO 14934–2 and ISO 14934–3, are constrained to lower irradiance levels and dependent on black body heat sources, limiting their applicability for high-intensity broadband irradiance measurements, particularly in concentrated solar applications. Here, to address this shortfall, the National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories (SNL) proposes a calibration method and facility capable of characterizing radiometers up to 2750 kW/m 2 using concentrated solar irradiance. Calibrating with concentrated sunlight is important for solar applications as it aligns the calibration process with the solar spectrum. This alignment is crucial for minimizing systematic errors and avoiding the need for additional corrections that may arise when radiometers designed for solar applications are calibrated using black-body or electrical sources. This paper presents the present day NSTTF characterization facility and procedure, detailing the proposed calibration method and uncertainty quantification. The presented method builds upon 1980′s NSTTF methodology and involves both theoretical and empirical methods to establish a robust relationship between gauge voltage output and irradiance intensity, quantifying both measurement and fitting errors. By addressing the limitations of existing standards and extending the characterization range, this work provides an advancement in the field of high-intensity irradiance measurement and instrumentation characterization.

Gardon gauge↗
NASA NTRSDate not supplied

Comparison of a Probabilistic TID Hardness Assurance Method to Military Standards

The rapid evolution of electronics has heralded countless benefits to humanity, enabling increases in computing power while decreasing costs. However, the constantly changing semiconductor device landscape proves to be an immense challenge for the reliability community, especially for those concerned with radiation effects on microelectronics. Changes in device manufacturing, from device structure to processing steps, may and often do change the way the device responds to radiation. While radiation hardened parts are not as much of a reliability concern, they also lag behind commercial off-the-shelf, or COTS, parts in terms of computing capabilities, some by over a decade. Many missions may have no choice but to utilize COTS. As such, these missions need to ensure their parts are reliable in the face of total ionizing dose (TID). However, part and testing facility costs limit the amount of testing possible.

Chloe Champagne↗
DOE OSTI2024

Recommended Actions to Improve Adapter Safety

With the rapid advancement and acceleration in the electric vehicle (EV) industry within the United States, major automakers and EV charging companies are increasingly adopting the North American Charging Standard (NACS) connector style, now officially known as J3400. This shift is expected to enhance charging infrastructure, providing a better customer experience by making it easier for all EV drivers to access a wider network of direct-current (DC) fast chargers (DCFCs). However, the adoption of the J3400 standard presents challenges for many EVs already on the roads and some currently coming off production lines that are equipped with the Combined Charging System (CCS) connector, which this report will refer to as the North American standard, CCS1. These vehicles will need adapters to use new or existing J3400 infrastructure. During this transition, several issues have emerged. Firstly, there is a need to standardize the new connector type to ensure it is interoperable, safe, and reliable. Second, existing CCS EV drivers need a way to access the J3400 network, which will require electric vehicle supply equipment (EVSE) or sites with both connector types, driver-provided adapters to physically convert from CCS to J3400, or EVSE with retained adapters designed for use with the EVSE. Third, adapter standards will need to be written to specify how they will be designed and what evaluations will be needed to ensure safe and reliable performance. To address these challenges, adapters that support different types of charging connectors will be essential. These adapters will play a crucial role in supporting the transition and ensuring continued service for legacy EVs with CCS inlets as the J3400 standard becomes the predominant one in the United States. Consequently, the National Charging Experience (ChargeX) Consortium has investigated and performed a teardown analysis on the different adapter versions on the market. The aim is to create a failure mode and effects analysis (FMEA) on what are expected to be the most common adapter types used in this transition. In order to support this work, we executed an FMEA exercise with the main goal of identifying gaps in the existing adapters' performance and conformance to the most common safety requirements of high-power and high-voltage devices. This effort focused on adapters provided by the driver, as these may present the highest safety and reliability risks. The recommendations made here apply to both retained and driver-provided adapters.

25 ENERGY STORAGE↗
DOE OSTI2023

Volt/VAR Optimization (VVO) Application on GridAPPS-D Platform

There is a large increment in the distributed energy resources (DERs) installation and deployments of smart sensing devices and communication infrastructure; hence, the power distribution network is swiftly evolving from a passive network to an active network. This motivates the development of advanced applications to operate power distribution systems for higher efficiency and reliability. These advanced applications are model-based and data-driven. This requires an advanced distribution management system (ADMS) to provide required data for the optimal operation of the distribution systems by coordinating various grid controllable devices. In this paper a Volt-VAR optimization (VVO) application to coordinate the grid’s legacy and new voltage control devices for conservation voltage reduction (CVR) is deployed on the GridAPPS-D platform (an open-source platform ) for ADMS application development. The VVO application is validated for various operating conditions on using modified IEEE 8500-node distribution test feeders. Further, the application is successfully deployed on the GridAPPS-D platform.

Jha, Rahul↗
DOE OSTI2022

Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology

The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Interdiffusion and Formation of Intermetallic Compounds in High-Temperature Power Electronics Substrate Joints Fabricated by Transient Liquid Phase Bonding

Power electronics packages typically comprise a dielectric substrate bonded to a metal layer and attached to heat sinks using a low-thermal-conductivity solder. These multiple layers increase the effective thermal resistance of the package and are responsible for package failures under cyclic thermal loads. Bonding the aluminum nitride dielectric layer (AlN) directly to a low coefficient of thermal expansion (CTE) aluminum silicon carbide (AlSiC) cold plate using copper-aluminum (Cu-Al) transient liquid phase (TLP) bonding has been shown to improve the mechanical reliability of the power electronic packages while making the package more compact by bringing the cooling solutions closer to the devices. This study aims to characterize the Cu-Al bonds formed during the TLP bonding of AlSiC with three different power electronics substrates: pure aluminum nitride (AlN), aluminum (DBA), and copper (DBC). The material compositions and microstructures of the bonds were analyzed using scanning electron microscopy (SEM), x-ray spectroscopy (EDS), confocal scanning acoustic microscopy (C-SAM), and x-ray diffraction (XRD). ..alpha..-Al solid compound was identified as the dominant phase in AlN-AlSiC and Al-AlSiC, with a notable presence of SiC particles. In contrast, three intermetallic phases - ..theta..-CuAl2, ..eta..-CuAl, and ..gamma..'- Cu9Al4 - were observed in the Cu-AlSiC bond. A computational solid-state diffusion model was developed to predict the intermetallic compounds (IMCs) formed during Cu-Al TLP bonding in each system, which supported the observation that an initial Cu volume fraction of 20 % in the material layers produced a final bond composition of >95 % Al with minimal IMC growth. However, increased Cu concentrations produced higher concentration gradients, leading to increased growth of IMCs, Kirkendall voids, and interstitial cracks.

DIRECT ENERGY CONVERSION↗
NASA NTRS1979

Transistor step stress program for JANTX2N4150

Reliability analysis of the transistor JANTX2N4150 manufactured by General Semiconductor and Transitron is reported. The discrete devices were subjected to power and temperature step stress tests and then to electrical tests after completing the power/temperature step stress point. Control sample units were maintained for verification of the electrical parametric testing. Results are presented.

Source record↗
NASA NTRS2003

Carbon Nanotube Electrode Arrays For Enhanced Chemical and Biological Sensing

Applications of carbon nanotubes for ultra-sensitive electrical sensing of chemical and biological species have been a major focus in NASA Ames Center for Nanotechnology. Great progress has been made toward controlled growth and chemical functionalization of vertically aligned carbon nanotube arrays and integration into micro-fabricated chip devices. Carbon nanotube electrode arrays devices have been used for sub-attomole detection of DNA molecules. Interdigitated carbon nanotubes arrays devices have been applied to sub ppb (part per billion) level chemical sensing for many molecules at room temperature. Stability and reliability have also been addressed in our device development. These results show order of magnitude improvement in device performance, size and power consumption as compared to micro devices, promising applications of carbon nanotube electrode arrays for clinical molecular diagnostics, personal medical testing and monitoring, and environmental monitoring.

Han, Jie↗
NASA NTRS2008

Closed-Cycle Hydrogen-Oxygen Regenerative Fuel Cell at the NASA Glenn Research Center-An Update

The closed cycle hydrogen-oxygen proton exchange membrane (PEM) regenerative fuel cell (RFC) at the NASA Glenn Research Center has demonstrated multiple back-to-back contiguous cycles at rated power and round-trip efficiencies up to 52 percent. It is the first fully closed cycle RFC ever demonstrated. (The entire system is sealed; nothing enters or escapes the system other than electrical power and heat.) During fiscal year fiscal year (FY) FY06 to FY07, the system s numerous modifications and internal improvements focused on reducing parasitic power, heat loss, and noise signature; increasing its functionality as an unattended automated energy storage device; and in-service reliability.

Bents, David J.↗
NASA NTRS2013

Bilayer Protograph Codes for Half-Duplex Relay Channels

Direct to Earth return links are limited by the size and power of lander devices. A standard alternative is provided by a two-hops return link: a proximity link (from lander to orbiter relay) and a deep-space link (from orbiter relay to Earth). Although direct to Earth return links are limited by the size and power of lander devices, using an additional link and a proposed coding for relay channels, one can obtain a more reliable signal. Although significant progress has been made in the relay coding problem, existing codes must be painstakingly optimized to match to a single set of channel conditions, many of them do not offer easy encoding, and most of them do not have structured design. A high-performing LDPC (low-density parity-check) code for the relay channel addresses simultaneously two important issues: a code structure that allows low encoding complexity, and a flexible rate-compatible code that allows matching to various channel conditions. Most of the previous high-performance LDPC codes for the relay channel are tightly optimized for a given channel quality, and are not easily adapted without extensive re-optimization for various channel conditions. This code for the relay channel combines structured design and easy encoding with rate compatibility to allow adaptation to the three links involved in the relay channel, and furthermore offers very good performance. The proposed code is constructed by synthesizing a bilayer structure with a pro to graph. In addition to the contribution to relay encoding, an improved family of protograph codes was produced for the point-to-point AWGN (additive white Gaussian noise) channel whose high-rate members enjoy thresholds that are within 0.07 dB of capacity. These LDPC relay codes address three important issues in an integrative manner: low encoding complexity, modular structure allowing for easy design, and rate compatibility so that the code can be easily matched to a variety of channel conditions without extensive re-optimization. The main problem of half-duplex relay coding can be reduced to the simultaneous design of two codes at two rates and two SNRs (signal-to-noise ratios), such that one is a subset of the other. This problem can be addressed by forceful optimization, but a clever method of addressing this problem is via the bilayer lengthened (BL) LDPC structure. This method uses a bilayer Tanner graph to make the two codes while using a concept of "parity forwarding" with subsequent successive decoding that removes the need to directly address the issue of uneven SNRs among the symbols of a given codeword. This method is attractive in that it addresses some of the main issues in the design of relay codes, but it does not by itself give rise to highly structured codes with simple encoding, nor does it give rate-compatible codes. The main contribution of this work is to construct a class of codes that simultaneously possess a bilayer parity- forwarding mechanism, while also benefiting from the properties of protograph codes having an easy encoding, a modular design, and being a rate-compatible code.

Divsalar, Dariush↗
DOE OSTI2022

High power targets: Challenges of next-generation high-intensity neutrino beams

High power target systems are crucial elements in enabling future neutrino and other rare particle beams. These systems transform intense source of protons into secondary particles of interest to enable new scientific discoveries. As primary beam intensities increase in next-generation multi-megawatt accelerator facilities, high power target systems face key challenges. Thermal shock and radiation damage effects in beam-intercepting devices were identified as the leading cross-cutting challenges of high-power target facilities. Target materials R&D to address these challenges are therefore essential to enable and ensure reliable operation of future accelerator target facilities. This paper provides an overview of the R&D activities underway to help support high power target systems development for next-generation multi-MW facilities.

43 PARTICLE ACCELERATORS↗