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DOE OSTI2020

Semiconductor power device including wire or ribbon bonds over device active region

A semiconductor power device including a base plate; an input lead; an output lead; a field effect transistor (FET) power die disposed over the base plate, wherein the FET power die includes a set of source fingers, a set of drain fingers, and a set of gate fingers disposed directly over an active region, wherein the gate fingers are configured to receive an input signal from the input lead, and wherein the FET power die is configured to process the input signal to generate an output signal at the drain fingers for routing to the output lead; and electrical conductors (wirebonds or ribbons) bonded to the source and/or drain directly over the active region of the FET power die. The electrical conductors produce additional thermal paths between the active region and the base plate for thermal management of the FET power die.

42 ENGINEERING↗

DOE OSTI2021

All-Source Competitive Solicitations: State and Electric Utility Practices

This report provides an overview of principles, practices, and emerging issues in all-source competitive solicitations. It reviews the history of electric utility all-source solicitations and recent results; provides an overview of goals, design tradeoffs, and stages; and examines solicitation design and implementation options and issues, including methodological issues around bid evaluation. The report draws on a review of regulatory documents, resource plans, solicitation materials, independent evaluator reports, and scholarly literature. While the report focuses on solicitations by investor-owned utilities for bulk power system needs, it also briefly discusses solicitations for non-wires alternatives for distribution system needs, as well as nascent practices for integrating both types of procurements.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

PETN Exploding Bridgewire (EBW) Detonators: A Review

Exploding bridgewire (EBW) detonators have been used in weapon systems since the 1940s but there is huge debate surrounding how energy is transferred throughout the EBW firing system and the mechanism by which the exploding wire leads explosive detonation. This report summarizes the underpinning technologies and physical processes that are currently understood and reviews the various efforts to quantify the mechanism by which the PETN is initiated. The behavior of the firing system is very well understood and predictable. The energy delivered to the wire has been empirically modelled but further investigation is required to understand the role of material heterogeneities and their effect on initiation. The energy delivered by the exploding wire has been quantified in many studies but it is not possible to correlate these to a particular design or firing regime and thus definitive conclusions are impossible. The energy absorbed by the PETN is also not well understood. Therefore, the initiation mechanism within the PETN EBWs has not been determined for EBW detonators. There is strong evidence that a shock-to-detonation (SDT) mechanism is not the sole cause of initiation. There is insufficient understanding of how electrical sparks transmit energy to PETN to make any judgement regarding the role gas ionization plays. Deflagration-to-detonation (DDT) seems like the most likely candidate for initiation but there is still a great lack of evidence for the presence of this mechanism.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2025

Superconducting properties of commercially available solders for low-field applications

Solders with superconducting transitions around 4K are useful in low magnetic field environments for AC current leads or in electrical and mechanical bonds. Accurate knowledge of these solders’ superconducting properties is essential for improving high precision experiments. We have measured the electrical resistance of five commercially-available eutectic or near-eutectic solders: 50%Sn-50%Pb, 60%Sn-40%Pb, 60%Sn-40%Pb-0.3%Sb, 52%In-48%Sn, and 96.5%Sn-3.5%Ag, down to 2.3K and in applied magnetic fields from 0 to 0.1 T . We report critical temperatures T c (B), 90%–10% transition widths ΔT c , and zero-temperature critical fields B c,0 . Our best candidate for low-loss AC current wiring in low fields is 50%Sn-50%Pb, which has a zero-field T c,0 = 7.1K (with ΔT c = 0.6 K), and remained high at T c (0.1 T) = 6.9K (ΔT c = 0.6K ). We also report, for the first time, T c and B c of 60%Sn-40%Pb-0.3%Sb and B c,0 of 96.5%Sn-3.5%Ag. Our T c,0 - 3.31K (ΔT c = 0.08K) for 96.5%Sn-3.5%Ag disagrees with a widely adopted value.

Hickman, C. [North Carolina State University, Rale↗

DOE OSTI2022

Solid Phase Processing of Lead-Free Brass with Carbon Additives

Currently, “lead-free” brass alloys (like C27450/C27451/C6930), used extensively in drinking water fixtures and automotive, electrical, and electronic applications contain maximum 0.25% lead to maintain mechanical performance and machinability. Adding graphite to brass as an alternative to lead, using casting, powder metallurgy, and extrusion methods, has been explored previously. However, all these methods have proven to be energy-, time-, and resource-intensive, while not enabling performance equivalent to that of C36000 brass. In this project, we developed a one-step approach using friction extrusion and ShAPE to make lead-free brass/graphite components such as wires, rods and tubes with mechanical performance equivalent to commercial lead-free brass alloys. Manufacturing temperatures were maintained ~550-730 °C with feed rates ranging between 4 – 25 mm/min. Results show larger grains at the center of the rods and wires with smaller grains developing at the edges. Graphite particles were sheared in the direction of extrusion with higher strains observed towards the edges. Hardness of the brass/graphite samples was over 25% higher than that of the corresponding brass-only samples (rods and wires), also friction extruded. Our results show that the sub-micron graphite plays an important role in limiting process temperature and restraining grain growth during friction extrusion, thus reducing grain size in composites.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗

DOE OSTI2024

, Experimental Investigation of Electrically Charged Water Droplets Two-Phase Cross-Flow Interactions with Humid

Electrically charged water droplets can capture water vapor molecules in surrounding moist air and promote vapor condensation. This concept unfolds an alternative to mechanical cooling-based air dehumidification systems that separate sensible and latent cooling loads in HVAC applications. The effect of dielectrophoresis, electro-hydrodynamic, and micro-diffusive flows due to highly electrically charged water droplets traveling through moist air were investigated as new methods to reduce the air’s water vapor content. This paper presents new experimental data on humidification and power consumption for a system consisting of highly energized electrosprays in combination with mist eliminators. Electrosprays produced highly charged water spray cones crossing the air perpendicularly and upwardly. The moist air stream was circulated in a horizontal duct at 22C, 80% relative humidity, and 0.24 ms-1 airspeed. Mist eliminators made of stainless wire clothes of 36 and 25 μm pore diameter were used to screen the droplets growing during their flight trajectory. The mist eliminators blocked some of the largest diameter droplets. Still, they could not prevent re-evaporation of the droplets into the bulk air from the droplets deposited on their wire clothes. The equilibrium between the dielectrophoresis condensation from the electrosprays and the droplets’ re-evaporation phenomena resulted in reduced humidification when compared to conventional-type spray evaporative cooling systems. However, to dehumidify the air, the droplets injected by the electrosprays must be separated entirely and promptly removed from the bulk airflow at the end of their flight trajectory.

Electrostatic droplets, Electrospray, humidificati↗

DOE OSTI2025

Improving Dynamic Wireless Charging System Performance For Electric Vehicles Through Variable Speed Limit Control Integration

Electric Vehicle (EV) charging has been a significant barrier to the widespread use of EVs. Traditional EV charging methods depend on cables, and there are concerns about safety, accessibility, convenience, and weather. A recent development, dynamic (or in-motion) wireless charging, enables EVs to charge wirelessly by incorporating charging infrastructure into roadways, allowing EVs to charge while moving. However, the energy transferred relies heavily on vehicle speed and time spent in the charging lane. This paper proposes an innovative solution that combines dynamic wire-less charging with Variable Speed Limit (VSL) control. This dynamic traffic control strategy adjusts speed limits based on real-time traffic, weather, and incidents. This integration of dynamic wireless charging and VSL has two potential benefits. First, it can motivate driver compliance with VSL through the incentive of charging. Second, it can promote smoother traffic flow and improve traffic safety by implementing lower speed limits at certain times. To verify these benefits, microscopic traffic simulations in SUMO were conducted under different EV penetration rates and VSL compliance rates. Simulation results reveal that the proposed approach can enhance dynamic wireless charging system performance while improving traffic flow and safety.

Xu, Guanhao [ORNL] (ORCID:0000000214326357)↗

DOE OSTI2020

Features of explosion of thin aluminum foils on an 8 kA, 350 ns pulse generator

This paper presents the results of a study of the explosion of Al foils with a thickness of 4 μm on an 8 kA, 350 ns pulsed-power generator. The features of the energy deposition process in the explosion of foils in comparison with wires of similar mass and cross section, as well as with thin wires, are studied. In the experiments presented here, the dependence of the energy deposition in the foil on its initial structure was found. In conclusion, two types of exploded foil structure were recorded using point-projection radiography

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Making Wireless Power Matter (CRADA Final Report)

The Resonant Link project team investigated the integration of their novel, self-resonant magnetic structure for electromagnetic coils into inductive wireless power transfer systems. Relative to conventional wireless power coils, their multi-layer self-resonant structure (the “MSRS”) reduces losses by up to 6x and lowers to BOM cost by up to 10x. These power-dense, cost-effective coils are a promising path towards the first value-add wireless power systems in a variety of applications, from phones to medical devices to kitchen appliances to mobile robots to electric vehicles. The researchers explored development of the power electronics for wireless power transfer systems using the multi-layer self-resonant structure (MSRS) concept that efficiently transmits power over air gaps for in-home applications, including through-wall power transfer, appliances built around the Ki and Qi standards, and other potential use cases This project specifically focused on the power electronics design, development, and testing for these applications. Resonant Link’s proprietary wireless power technology holds the promise of matching the performance of wired chargers in size and efficiency, especially when operated from a DC distribution grid.

42 ENGINEERING↗

DOE OSTI2025

OPET Hardware (Open PV Electrical Tool Hardware) [SWR-25-42]

OPET (Open-source Photovoltaic Electrical Tool) is used for performance measurements of solar photovoltaic (PV) devices in the field under natural sunlight or in the lab under artificial light. Its primary use is in research and development of solar cells and modules, specifically in reliability and durability research of PV devices. Some features and functions include: -IV curve measurements with linear or cosine distributed measurement points -PV device active loading at open circuit voltage (Voc), short circuit current (Isc) and maximum power point (Pmp) -Bias power supply to overcome series resistance in contact wires for Isc measurements and loading -PV voltage input in five ranges from 1V to 100V -PV current input ranges -Low current version, six current ranges from 1.1mA to 340mA -High current version, six current ranges from 50mA to 15A -IO ports for I2C and SPI temperature sensor Arduino extension boards -Integrated fan control This repository contains everything relating to the hardware of the OPET device. If you are looking for the firmware or software repositories, links are below: https://github.com/NREL/opet-firmware https://github.com/NREL/opet-control

McDanold, Byron [National Renewable Energy Laborat↗

DOE OSTI2023

Design, Modeling, and Testing of a Novel Inductor for Electric Vehicles: Iron Nitride Soft Magnetic Composites

New technology for electric vehicles (EVs) must meet the requirements of higher energy usage, lower costs, and more sustainable source materials. One promising material for EV power system components is iron nitride (IN) soft magnetic composites (SMCs) because of their competitive magnetic properties and high abundance of the source materials. As part of an ongoing program at Sandia National Laboratories, this project focused on using computer modeling to optimize the prototyping process for an iron nitride SMC toroidal inductor to reach a target inductance of 600 μH. Four inductors with different combinations of wiring (26 AWG and 20 AWG) and vol% loading of iron nitride (65 vol% and 50 vol%) were fabricated at Cal Poly and characterized using an LCR meter. These inductors were also modeled using COMSOL Multiphysics™ with the Magnetic Fields module. The inductance data from the experiment and the model show that the 65 vol% IN prototypes and models agree with about 8% difference, while the 50 vol% IN samples show about a 9% difference between the prototype and the model. These results suggest that the model can predict inductance with both accuracy and precision with low confidence for the given sample size of four. An additional parameter of AC resistance is studied but the AC resistance results from the inductors and from the model generally do not agree closely, suggesting that the current model used in the project does not fully capture the mechanisms behind AC resistance of the inductor. With the focus of the project on inductance, the percent difference results of less than 9% across the four inductors that were tested increases confidence in the model’s predictive capabilities for inductance only. Using the inductance results from both the model and experiment, the final suggested inductor design is a 65 vol% core with 150 windings of 20 AWG wire that is 8 cm across and 1.5 cm tall to reach the inductance goal of 600 μH based on analysis using the optimized COMSOLTM model.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Quantum limits of superconducting-photonic links and their extension to millimeter waves

Photonic addressing of superconducting circuits has been proposed to overcome wiring complexity and heat-load challenges. However, such superconducting-photonic links suffer from an efficiency-noise trade-off that limits scalability. This trade-off arises because increasing power conversion efficiency entails reducing optical power, which makes the converted signal susceptible to shot noise. We analyze this trade-off and find that the laser-driven qubit gate infidelity scales inversely with the number of photons used. While methods such as nonlinear detection or squeezed light could mitigate this effect, we consider generating higher-frequency electrical signals, such as millimeter waves (100 GHz), using laser light. At these higher frequencies, circuits have higher operating temperatures and cooling power budgets and alleviate constraints posed by the trade-off. Therefore, we demonstrate an optically driven cryogenic millimeter-wave source with a maximum power efficiency of 8 ×10 −5 that can generate a maximum of 0.7 μ⁢W of 80 GHz power, with a 1200-thermal-photon equivalent of added noise at 4K. Using this source, we perform frequency-domain spectroscopy of superconducting NbTiN resonators at 80–90 GHz. Our results show a promising approach to lessen the efficiency-noise constraints on superconducting-photonic links, while leveraging the benefits of photonic signal delivery. Further optimization of power efficiency and noise at high frequencies could make scalable photonic control of superconducting qubits viable at temperatures exceeding 1K.

Optoelectronics↗

DOE OSTI2025

Uniform field in microwave cavities through the use of effective magnetic walls

Wire medium (WM) resonators have emerged as a promising realization for plasma haloscopes—devices designed to detect axions, a potential component of dark matter. Key factors influencing the detection probability include cavity volume, resonance quality factor, and form factor. While the form factor has been explored for resonant frequency tuning, its optimization for axion detection remains unexplored. Here, in this work, we present an approach to significantly enhancing the form factor of WM plasma haloscopes. By shifting the metal walls of the resonator by a quarter wavelength, we effectively convert an electric wall boundary condition into a magnetic wall one, allowing for an almost uniform mode. Theoretical analysis and numerical simulations confirm that this modification improves the electric field profile and boosts the form factor, while also slightly enhancing the quality factor. We validate these findings through experimental results from two prototype resonators: one with a standard geometry and another with a quarter-wave air gap between the WM and the walls. Additionally, our method provides a simple way to control the field profile within WM cavities, which can be explored for further applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Powering the Woods Hole X-Spar Buoy with Ocean Wave Energy—A Control Co-Design Feasibility Study

Despite its success in measuring air–sea exchange, the Woods Hole Oceanographic Institution’s (WHOI) X-Spar Buoy faces operational limitations due to energy constraints, motivating the integration of an energy harvesting apparatus to improve its deployment duration and capabilities. This work explores the feasibility of an augmented, self-powered system in two parts. Part 1 presents the collaborative design between X-Spar developers and wave energy researchers translating user needs into specific functional requirements. Based on requirements like desired power levels, deployability, survivability, and minimal interference with environmental data collection, unsuitable concepts are pre-eliminated from further feasibility study consideration. In part 2, we focus on one of the promising concepts: an internal rigid body wave energy converter. We apply control co-design methods to consider commercial of the shelf hardware components in the dynamic models and investigate the concept’s power conversion capabilities using linear 2-port wave-to-wire models with concurrently optimized control algorithms that are distinct for every considered hardware configuration. During this feasibility study we utilize two different control algorithms, the numerically optimal (but acausal) benchmark and the optimized damping feedback. We assess the sensitivity of average power to variations in drive-train friction, a parameter with high uncertainty, and analyze stroke limitations to ensure operational constraints are met. Our results indicate that a well-designed power take-off (PTO) system could significantly extend the WEC-Spar’s mission by providing additional electrical power without compromising data quality.

autonomous systems↗

DOE OSTI2021

Considerations and recent advances in nanoscale interfaces with neuronal and cardiac networks

Nanoscale interfaces with biological tissue, principally made with nanowires (NWs), are envisioned as minimally destructive to the tissue and as scalable tools to directly transduce the electrochemical activity of a neuron at its finest resolution. This review lays the foundations for understanding the material and device considerations required to interrogate neuronal activity at the nanoscale. We first discuss the electrochemical nanoelectrode-neuron interfaces and then present new results concerning the electrochemical impedance and charge injection capacities of millimeter, micrometer, and nanometer scale wires with Pt, PEDOT:PSS, Si, Ti, ITO, IrO x , Ag, and AgCl materials. Using established circuit models for NW-neuron interfaces, we discuss the impact of having multiple NWs interfacing with a single neuron on the amplitude and temporal characteristics of the recorded potentials. We review state of the art advances in nanoelectrode-neuron interfaces, the standard control experiments to investigate their electrophysiological behavior, and present recent high fidelity recordings of intracellular potentials obtained with ultrasharp NWs developed in our laboratory that naturally permeate neuronal cell bodies. Recordings from arrays and individually addressable electrically shorted NWs are presented, and the long-term stability of intracellular recording is discussed and put in the context of established techniques. Finally, a perspective on future research directions and applications is presented.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

Accurately measuring the ionic conductivity of membranes via the direct contact method

Accurately measuring the ionic conductivity of membranes is important both for assessing the performance of new membranes as well as for advancing the fundamental understanding of electric field-driven ion transport in membranes. Yet, despite a considerable number of reports on the topic, there is no standardized method for ionic conductivity measurements. One of the main challenges with ionic conductivity measurements is isolating the membrane resistance from the other resistances in the electrochemical cell. In this study, we present a detailed discussion of factors that affect ionic conductivity measurements with the commonly used direct contact method, in which the membrane contacts the electrodes. Such factors include external resistances due to imperfect contact between the membrane and electrodes, residual impedances due to the sample holder and wiring, and fringe effects. Further, we also present and validate simple methods for isolating the true membrane ionic conductivity in both the through-plane and in-plane orientations. These methods can be implemented with virtually any membrane to obtain accurate and reproducible ionic conductivity values. Finally, we outline recommendations for performing ionic conductivity measurements with the direct contact method and a set of parameters to verify when reporting these results.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Graphene-Based Interconnect Exploration for Large SRAM Caches for Ultrascaled Technology Nodes

Graphene-based interconnects are considered promising replacements for traditional copper (Cu) interconnect due to their great electric properties. In this article, an interconnect-memory co- design framework is developed to efficiently optimize various graphene-based interconnect technologies. Four interconnect materials and heterogeneous design schemes are benchmarked against their traditional Cu counterparts to optimize large cache-level SRAM performance in terms of delay and energy per access, energy-delay product (EDP), and energy-delay-area product (EDAP). Here, a large design space exploration is performed based on realistic subarray design and device technology. Various interconnect- and array-level design parameters are studied to quantify the true potential of graphene-based wires for optimal memory performance.

42 ENGINEERING↗