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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

650V SiC Integrated Power Module for Automotive Inverters

The Delphi team, including CREE/Wolfspeed for SiC power devices, with packaging by Delphi supported by Oak Ridge National Laboratory, and guidance from Volvo and other OEMs resulted in a robust, high performance integrated double-side cooled SiC-based Power Module that meets or exceeds the targets identified by DOE in the original FOA. The double-side cooled packages were designed to be scalable for voltages up to 800V and for phase currents up to 500Arms and that can be paralleled for currents up to 90Arms. These modules were confirmed and demonstrated in a traction drive inverter intended for an inverter for a specific OEM vehicle application and showed improved performance as compared to inverter systems with silicon based IGBTs and Diode with losses 70% lower at lower currents and up to 40% lower at peak current levels. This teaming resulted in a WBG integrated power module to be used in an inverter manufactured in Kokomo, Indiana, which will be manufacturable in volume at a cost that will enable reduced vehicle to cost improved performance, particularly by reducing weight and space-claim for the power electronics, as well as improving reliability overall. The targeted use of this developed power module is for a vehicle traction drive to be manufactured in the CY 2021 timeframe. The direct impact of this project will accelerate commercialization of advanced wide bandgap power semiconductor technology for electrified vehicles of all types, increasing their energy efficiency and marketability. In turn, more efficient and more marketable electrified vehicles will have the overall impact of reducing greenhouse gas emissions and other air pollutants, along with reducing our nation’s dependence on foreign energy sources.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Technoeconomic Analysis (TEA)

Techno-economic analysis (TEA) for the DuraMAT Consortium includes the following areas: linking solar photovoltaic (PV) technology trends to reliability implications; providing a framework to calculate technology costs, yielding insights useful for research decision-making, proposals, technology selection, and publications; and examining technology tradeoffs considering lifecycle project economics. This poster highlights results from the first and second iterations of the DuraMAT Technology Scouting reports as well as the updated Simplified PV Levelized Cost of Energy (LCOE) Calculator.

14 SOLAR ENERGY↗
DOE OSTI2018

Feasibility and Reliability of a Single Layer Polymeric PV Backsheet in White, Transparent, or Luminescent Concentrator Options

A single layer polymeric backsheet material has been evaluated for use in silicon PV modules and as a luminescent solar collector. Physical and optical properties of the backsheet have been examined after damp heat, thermal cycling, and UV exposure for two different polymeric grades and three different pigment options including white, transparent, and photo-luminescent. As the importance of developing a white backsheet that is cost-effective, recyclable, and reliable is evident, the increased availability and use of bifacial cells is bound to increase the demand for transparent backsheets as well. In today's market, the cost of a clear backsheet is significantly higher than a white backsheet which is motivation for research and development of new material options in this field. Results from these extensive tests reveal the need for continued research in white pigments and positive results in transparent and luminescent backsheet options.

14 SOLAR ENERGY↗
DOE OSTI2021

Packaging of an 8-kV Silicon Carbide Diode Module with Double-Side Cooling and Sintered-Silver Joints

Packaging innovations are needed for medium-voltage wide bandgap power semiconductor modules to enable their adaptation in grid applications. A unique challenge for packaging medium-voltage power modules is managing the trade-off between insulation demand and heat dissipation. The focus of this work was on developing a packaging innovation that improves the module heat dissipation and offers more flexibility to its insulation design. Two strategies were explored for the packaging of an 8-kV SiC diode rectifier module:(1) double-side cooling and (2) sintered-silver bonding. Double-side cooling was realized by using short metal posts rather than long and thin wire bonds for device interconnection, forming a low-profile package with devices sandwiched between two insulated metal substrates. Sintered-silver bonding enabled the devices to function reliably at over 250 °C. Simulations of the packaged module showed a low interconnect inductance of 2.67 nH and a 50% less heat transfer coefficient required to cool the chips. Prototypes of the module were fabricated, and preliminary electrical testing results validated the package design.

27 ARPA - Advanced Research Projects Agency-Energy↗
DOE OSTI2023

Fully Inkjet‐Printed, 2D Materials‐Based Field‐Effect Transistor for Water Sensing

Abstract Despite significant progress in solution‐processing of 2D materials, it remains challenging to reliably print high‐performance semiconducting channels that can be efficiently modulated in a field‐effect transistor (FET). Herein, electrochemically exfoliated MoS 2 nanosheets are inkjet‐printed into ultrathin semiconducting channels, resulting in high on/off current ratios up to 10 3 . The reported printing strategy is reliable and general for thin film channel fabrication even in the presence of the ubiquitous coffee‐ring effect. Statistical modeling analysis on the printed pattern profiles suggests that a spaced parallel printing approach can overcome the coffee‐ring effect during inkjet printing, resulting in uniform 2D flake percolation networks. The uniformity of the printed features allows the MoS 2 channel to be hundreds of micrometers long, which easily accommodates the typical inkjet printing resolution of tens of micrometers, thereby enabling fully printed FETs. As a proof of concept, FET water sensors are demonstrated using printed MoS 2 as the FET channel, and printed graphene as the electrodes and the sensing area. After functionalization of the sensing area, the printed water sensor shows a selective response to Pb 2+ in water down to 2 ppb. This work paves the way for additive nanomanufacturing of FET‐based sensors and related devices using 2D nanomaterials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The Sustainable Decarbonization Challenge

Many countries have decarbonization plans that include transitioning to clean energy. Because of this, PV deployment is projected to at least double or triple in the next ten years. As we ramp up manufacturing and deployment, we aim to sustainably establish secure and just supply chains while reducing environmental impacts. This talk presents our analysis of the virgin material demands, addresses waste concerns regarding quantity and toxicity, and establishes sustainability actions that the PV community can take to ensure sustainability. The takeaway actions are prioritizing reliable, high-quality, and long-lived PV modules and enabling the fast deployment needed for decarbonization via more research and effective communication.

circular economy↗
DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗
DOE OSTI2019

Updates on the Progress of the Alternate Topology Modulator (AT-HVCM) to support the Proton Power Upgrade (PPU) at the Spallation Neutron Source

The AT-HVCM, achieved by series-stacking the dual-function resonant filter capacitors following each rectification stage, is the baseline design for the PPU project at the SNS [1]. The project requires three AT-HVCM modulators to power 28 additional 700kW klystrons and associated high beta cavities to accelerate 38mA of beam current to 1.3GeV. Each modulator produces an 82 kV, 120A output pulse of 1.35ms duration at a 60Hz repetition rate. The AT design approach improves upon the existing HVCM topology, reducing stresses on the H bridge IGBTs using zero voltage (ZVS) and current switching (ZCS) techniques and on the resonant filter capacitors by limiting voltage reversal. This paper reviews the prototype development progress, currently focused on evaluating system reliability, and discusses some design techniques to achieve the modulator performance requirements.

Solley, Dennis J.↗
DOE OSTI2023

Single and Double-Sided Jet Impingement Cooling for SiC-Based Power Modules

Efficient thermal management of power electronics systems is crucial for higher reliability. With the miniaturization of systems, high-loss-density electronics require cooling systems that can extract a large amount of heat. This study explored a liquid-jet-impingement-based direct substrate cooling system for single-sided and double-sided cooling to improve heat extraction efficiency and improve the power density by reducing the volume and mass. The cooling system was implemented for a SiC-based direct bonded copper substrate. Numerical simulations were performed to determine the effects of nozzle diameter, the number of nozzles, and nozzle array orientation on single-sided cooling and thermal performance gain over double-sided cooling. A novel manifold design was proposed that reduced the volume and mass of the manifold and still achieved the target power density. The performance of the proposed design was compared with the pin-fin-based cooling system used in the BMW I3 module, and a comparative analysis was done.

Barua, Himel↗
DOE OSTI2019

Ground sculpting to enhance energy yield of vertical bifacial solar farms

The prospect of additional energy yield and improved reliability have increased commercial interest in bifacial solar modules. Recent publications have quantified the bifacial gain for several configurations. For example, a standalone, optimally-tilted bifacial panel placed over a flat ground (with 50% albedo) is expected to produce a bifacial energy gain of 30% (per module area). In contrast, self and mutual shading in a farm with periodically spaced panels reduces the bifacial gain to 10–15% (per farm area). Bifacial gain is negligible for vertical arrays—although the configuration is of significant interest since it can prevent soiling. Here, we calculate the bifacial gain of a solar farm where vertical arrays are placed over sculpted/patterned ground. We conclude that vertical panels straddling (upward) triangle-shaped ground maximizes the energy output. Our worldwide calculation with up-triangle ground configuration and 50% albedo leads to the following conclusion. Compared to a traditional tilted monofacial design, the bifacial gain is (i) small up to 20° latitude, (ii) increases to 50% at 40° latitude, and (iii) reaches up to 100% at 60° latitude. Overall, high bifacial gains are observed in many regions particularly those with moderate to low clearness index. The enhanced output, along with reduced soiling loss and lower cleaning cost of the ground sculpted vertical bifacial (GvBF) solar farm could be of significant technological interest, especially in regions such as the Middle East and North Africa (MENA) susceptible to significant soiling losses.

14 SOLAR ENERGY↗
DOE OSTI2019

Feedback control of stored energy and rotation with variable beam energy and perveance on DIII-D

Design and testing of a new method for real-time control on DIII-D using the new voltage and perveance variation capability of DIII-D's neutral beam injection system is presented. The approach enables control of power, torque, stored energy, and rotation without requiring pulse-width modulation of the beams. Such modulations are perturbative to experiments, can cause beam reliability problems, and could potentially damage or fatigue accelerator grids, especially looking forward to active control of long-pulse devices and reactors. Here, the control algorithm accounts for beam line loss mechanisms and includes approaches that address the complexity of having three manipulated variables for each of the eight beams and compensate for the rate and magnitude limits affecting the voltage and perveance actuators. Results are presented that demonstrate the performance of the approach in the first feedback control experiments to use the expanded controllability of the DIII-D beams.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2012

Demonstration of a Novel Synchrophasor-based Situational Awareness System: Wide Area Power System Visualization, On-line Event Replay and Early Warning of Grid Problems

Since the large North Eastern power system blackout on August 14, 2003, U.S. electric utilities have spent lot of effort on preventing power system cascading outages. Two of the main causes of the August 14, 2003 blackout were inadequate situational awareness and inadequate operator training In addition to the enhancements of the infrastructure of the interconnected power systems, more research and development of advanced power system applications are required for improving the wide-area security monitoring, operation and planning in order to prevent large- scale cascading outages of interconnected power systems. It is critically important for improving the wide-area situation awareness of the operators or operational engineers and regional reliability coordinators of large interconnected systems. With the installation of large number of phasor measurement units (PMU) and the related communication infrastructure, it will be possible to improve the operators’ situation awareness and to quickly identify the sequence of events during a large system disturbance for the post-event analysis using the real-time or historical synchrophasor data. The purpose of this project was to develop and demonstrate a novel synchrophasor-based comprehensive situational awareness system for control centers of power transmission systems. The developed system named WASA (Wide Area Situation Awareness) is intended to improve situational awareness at control centers of the power system operators and regional reliability coordinators. It consists of following main software modules: • Wide-area visualizations of real-time frequency, voltage, and phase angle measurements and their contour displays for security monitoring. • Online detection and location of a major event (location, time, size, and type, such as generator or line outage). • Near-real-time event replay (in seconds) after a major event occurs. • Early warning of potential wide-area stability problems. The system has been deployed and demonstrated at the Tennessee Valley Authority (TVA) and ISO New England system using real-time synchrophasor data from openPDC. Apart from the software product, the outcome of this project consists of a set of technical reports and papers describing the mathematical foundations and computational approaches of different tools and modules, implementation issues and considerations, lessons learned, and the results of lidation processes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Extended Pulse-Powered Humidity-Freeze Cycling for Testing Module-Level Power Electronics

An EMI suppression capacitor (polypropylene film type) failed by 'popcorning' due to vapor outgassing in pulse powered humidity-freeze cycles. No shorts or shunts could be detected despite mildly corroded metallization visible in the failed capacitor. Humidity-freeze cycling is optimized to break into moisture barriers. However, further studies will be required on additional module level power electronic (MLPE) devices to optimize the stress testing for condensation to precipitate any weakness to short circuiting and other humidity/bias failure modes.

14 SOLAR ENERGY↗
DOE OSTI2024

Development and Reliability of Screen-Printable Fire-Through Cu Paste for Passivated Contact Solar Cells

We present the development of copper (Cu) paste which has been screen printed on Selective Emitter-Passivated Emitter Rear Contact (SE-PERC) solar cells. This paste can also be applied to Tunnel Oxide Passivated Contact (TOPCON) solar cells due to its fire-through nature. Champion PERC cells have achieved ....efficiency with ...parameters . Accelerated testing to investigate reliability performance of the SE- PERC mini-modules were carried out in damp heat chamber with 85oC and 85% humidity. The devices were found to be operational even after 1,500 hours. Devices with screen printed Ag contacts on the front side have been studied in parallel to the Cu contacts for comparison.

copper paste↗
DOE OSTI2012

Reliable detection of fluence anomalies in EPID-based IMRT pretreatment quality assurance using pixel intensity deviations

Purpose: This work uses repeat images of intensity modulated radiation therapy (IMRT) fields to quantify fluence anomalies (i.e., delivery errors) that can be reliably detected in electronic portal images used for IMRT pretreatment quality assurance. Methods: Repeat images of 11 clinical IMRT fields are acquired on a Varian Trilogy linear accelerator at energies of 6 MV and 18 MV. Acquired images are corrected for output variations and registered to minimize the impact of linear accelerator and electronic portal imaging device (EPID) positioning deviations. Detection studies are performed in which rectangular anomalies of various sizes are inserted into the images. The performance of detection strategies based on pixel intensity deviations (PIDs) and gamma indices is evaluated using receiver operating characteristic analysis. Results: Residual differences between registered images are due to interfraction positional deviations of jaws and multileaf collimator leaves, plus imager noise. Positional deviations produce large intensity differences that degrade anomaly detection. Gradient effects are suppressed in PIDs using gradient scaling. Background noise is suppressed using median filtering. In the majority of images, PID-based detection strategies can reliably detect fluence anomalies of {>=}5% in {approx}1 mm{sup 2} areas and {>=}2% in {approx}20 mm{sup 2} areas. Conclusions: The ability to detect small dose differences ({<=}2%) depends strongly on the level of background noise. This in turn depends on the accuracy of image registration, the quality of the reference image, and field properties. The longer term aim of this work is to develop accurate and reliable methods of detecting IMRT delivery errors and variations. The ability to resolve small anomalies will allow the accuracy of advanced treatment techniques, such as image guided, adaptive, and arc therapies, to be quantified.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Rapid Electrochemical Diagnosis of Battery Health and Safety from Cells to Modules

Rapid electrochemical diagnosis of battery health and failure is critical for ensuring reliable battery performance and battery safety. Traditional battery health diagnostics such as capacity measurements and DC pulse tests are reliable and well-understood, however, these measurements of battery capacity and resistance do not capture all aspects of battery degradation. Other aspects of degradation, such as electrolyte decomposition, lithium-plating, and particle cracking are difficult to detect electrochemically but are crucial to measure to get a full picture of battery safety and flag out potential failures. In this work, lab- and field-aged commercial lithium-ion batteries and modules of various chemistries and formats are tested using a variety of traditional electrochemical characterization methods as well as using 2-minute pseudo-random DC pulse sequences at rest and during charge/discharge. The electrochemical measurements are compared to physical cell measurements, cell efficiency, drive cycle performance, physical and thermal heterogeneity, and qualitative safety metrics using statistical and machine-learning methods to discover if a comprehensive "battery health map" can be accurately identified using only rapid DC measurements.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗
DOE OSTI2018

Impact of threading dislocation density on the lifetime of InAs quantum dot lasers on Si

We investigate the impact of threading dislocation density on the reliability of 1.3 μm InAs quantum dot lasers epitaxially grown on Si. A reduction in the threading dislocation density from 2.8 × 108 cm−2 to 7.3 × 106 cm−2 has improved the laser lifetime by about five orders of magnitude when aged continuous-wave near room temperature (35 °C). We have achieved extrapolated lifetimes (time to double initial threshold) more than 10 × 106 h. An accelerated laser aging test at an elevated temperature (60 °C) reveals that p-modulation doped quantum dot lasers on Si retain superior reliability over unintentionally doped ones. These results suggest that epitaxially grown quantum dot lasers could be a viable approach to realize a reliable, scalable, and efficient light source on Si.

Jung, Daehwan↗