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At least 37 records · Page 2

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DOE OSTI2021

Characterization of Highly Thermally Conductive Organic Substrates for a Double-Sided Cooled Power Module

Abstract Silicon-Carbide (SiC) power devices have become a promising option for traditional Silicon (Si) due to the superior material properties. To fully take advantage of the SiC devices, a high-performance power device packaging solution is necessary. This study proposes a cost-effective double-sided cooled (DSC) 1.2 kV SiC half-bridge power module using organic epoxy-resin composite dielectric (ERCD) substrates. The high mechanical and thermal performance of the power module is achieved by the low-modulus, moderate thermal conductivity, and relatively thin (120 μm) layer of ERCD material compared with traditional metal-clad ceramic approaches. This novel organic dielectric can withstand high voltage (5 kV @ 120 μm) and operate up to 250°C continuously, which is indispensable for high power applications. The thermal modeling results show that the equivalent thermal resistance junction-to-case (Rjc_eq) of the DSC power module using dual direct bonded copper (DBC) is 17% higher than the dual ERCD configuration. Furthermore, a non-insulated DSC power module concept is proposed for maximizing thermal performance by considering thermal vias in the ERCD substrate and direct-soldered heat sink. A thought process for optimization of thermal via design is demonstrated and it shows up to 24% of improvement on thermal performance compared with the insulated DSC power module.

Double-sided cooling, epoxy-resin composite dielec↗

DOE OSTI2023

Cooling performance of an active-passive hybrid composite phase change material (HcPCM) finned heat sink: Constant operating mode

Here, the present study explores a hybrid thermal management technology based on air cooling and hybrid composite phase change material (HcPCM) filled finned heat sink for cooling performance of lower to medium heat flux dissipating electronic devices. Two-dimensional numerical simulations are conducted to study the conjugate heat transfer effects of three types of finned heat sink: air-cooled finned heat sink, HcPCM-cooled finned heat sink, and hybrid (air-HcPCM) cooled finned heat sink. A heat sink with a constant volume faction of plate-fins is designed in all cases and simultaneous effects of hybrid nanoparticles and air are investigated to keep the heat sink temperature at safe operating conditions between 40–60°C. The effect of air is incorporated into the heat sink by applying the convective heat transfer coefficient of h c = 10–100W /m 2 .K which tends to create the natural convection and forced convection heat transfer characteristics. The heat flux is varied from 25–40kW /m 2 in the current study. The hybrid nanoparticles of carbon additives (GO and MWCNTs) are dispersed into the RT-35HC, used as a PCM, with a volume fraction of 0% to 6%. Transient simulations are carried out using COMSOL Multiphysics to solve the governing equations for PCM based conjugate heat transfer model. The results showed that forced convection heat transfer improved the cooling performance of the hybrid heat sink compared to natural convection heat transfer. The addition of nanoparticles further enhanced thermal enhancement and uniform melting distribution of PCM inside the finned heat sink. The h c between 30 to 50W/m 2 .K shows optimized values for forced convection heat transfer operating conditions. The volume fraction of 2% of GO+MWCNTs nanoparticles in recommended or optimum concentration for uniform melting of PCM inside the finned heat sink.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design, fabrication, simulation, and testing of additively manufactured lattice-based copper heat sinks

Here, this study investigates the potential advantages of lattice structure-based bound metal material extrusion (MEX) 3D printing for fabricating high-performance copper heat sinks. Copper powder-filled polymer filaments, with a copper content of > 90 wt.%, were developed specifically for the bound metal MEX 3D printing process. Three types of structures—planar, strut, and surface lattices—were 3D printed to facilitate efficient heat transfer pathways within the heat sinks. Subsequent post-processing steps, including polymer removal and sintering, were performed to achieve dense copper parts. Hot isostatic pressing was further employed to enhance the sintered density from 93 to 98%. Finite element analysis (FEA) simulations were conducted to assess the heat transfer efficiency of the designs, and heat transfer experiments were performed using a custom setup to validate the simulation results. Additionally, this research explores the use of extended hold times during pre-sintering and a reduced atmosphere to enhance the %IACS values (electrical conductivity) and thermal performance of the bound metal MEX 3D printed copper heat sinks. The investigation combines experimental analysis, including simulations and heat transfer experiments, to gain insights into the structure-material property relationships and optimize the thermal performance of the printed heat sinks.

Ajjarapu, Kameswara Pavan Kumar [Oak Ridge Nationa↗

NASA NTRS2024

x Thermal Straps

Thermal straps, also known as heat straps or flexible conductive links, offer design solutions for enhancing the thermal bond of two items that may need to be mechanically decoupled. The need for mechanical decoupling can be driven by requirements for things like vibration or load isolation, or simply by packaging constraints. A few examples include thermal straps used to mechanically isolate delicate spaceborne detectors from cryocooler vibrations, or thermal straps coupling a high-dissipation electronic component to a heat sink on an adjacent surface in a volume optimized electronics unit.

thermal, heat transfer, straps↗

DOE OSTI2021

Analysis and Optimization of a Multi-Layer Integrated Organic Substrate for High Current GaN HEMT-Based Power Module

In this paper, analysis and optimization of a multi-layer organic substrate for high current GaN HEMT based power module are discussed. The organic multi-layer substrates can provide high electrical performance in terms of low parasitic inductance in the power loop by providing vertical layout, and shielding for reduction of common-mode noise, a common problem in fast switching power converters. Furthermore, high performance cooling solutions, such as micro-channel heat sinks, can be directly bonded to the substrate for optimum thermal management. The structure of the proposed architecture, thermal analysis and optimization of layer thickness, thermo-mechanical stress analysis of the GaN HEMT and development of a high-performance heat sink are discussed.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2010

Phase Change Material Trade Study: A Comparison Between Wax and Water for Manned Spacecraft

Phase change material heat sinks have been recognized as an important tool in optimizing thermal control systems for space exploration vehicles and habitats that must deal with widely varying thermal loads and environments. In order to better focus technology investment in this arena, NASA has supported a trade study with the objective of identifying where the best potential pay-off can be found among identified aqueous and paraffin wax phase change materials and phase change material heat sink design approaches. The study used a representative exploration mission with well understood parameters to support the trade. Additional sensitivity studies were performed to ensure the applicability of study results across varying systems and destinations. Results from the study indicate that a water ice PCM heat sink has the potential to decrease the equivalent system mass of the mission s vehicle through a combination of a smaller heat sink and a slight 5% increase in radiator size or the addition of a lightweight heat pump. An evaluation of existing and emerging PCM heat sink technologies indicates that further significant mass savings should be achievable through continued development of those technologies. The largest mass savings may be realized by managing the location of the liquid and the solid in the heat sink to eliminate the melting and freezing pressure of wax and water, respectively, while also accommodating the high structural loads expected on future manned launch vehicles.

Quinn, Gregory↗

NASA NTRS2011

Phase Change Material Trade Study: A Comparison Between Wax and Water for Manned Spacecraft

Phase change material heat sinks have been recognized as an important tool in optimizing thermal control systems for space exploration vehicles and habitats that must deal with widely varying thermal loads and environments. In order to better focus technology investment in this arena, NASA has supported a trade study with the objective of identifying where the best potential pay-off can be found among identified aqueous and paraffin wax phase change materials and phase change material heat sink design approaches. The study used a representative exploration mission with well understood parameters to support the trade. Additional sensitivity studies were performed to ensure the applicability of study results across varying systems and destinations. Results from the study indicate that replacing a wax PCM heat sink with a water ice PCM heat sink has the potential to decrease the equivalent system mass of the mission s vehicle through a combination of a smaller heat sink and a slight 5% increase in radiator size or the addition of a lightweight heat pump. An evaluation of existing and emerging PCM heat sink technologies indicates that further mass savings should be achievable through continued development of those technologies. The largest mass savings may be realized by eliminating the melting and freezing pressure of wax and water, respectively.

Quinn, Gregory↗

DOE OSTI2020

Thermal Design Consideration of Medium Voltage High Frequency Transformers

This paper describes a thermal design using epoxy potting for high frequency transformer (HFT) for medium voltage high power electronic applications, namely emerging solid-state transformers. To address HFT’s thermal stress problem, thermal performance of the HFT with air and epoxy potting cooling method are both simulated by magnetothermal-fluid coupling method (MTFCM). The effectiveness of the simulation analysis is verified in a 100 kW DC-DC resonant converter. Influencing factors including distance between the high frequency transformer and the metal enclosure, epoxy thermal conductivity and heat sink placements are simulated and analyzed. Finally, an optimal cooling structure is proposed for future high power HFTs.

Wang, Haoming↗

NASA NTRS2000

Variable Emissivity Through MEMS Technology

This paper discusses a new technology for variable emissivity (vari-e) radiator surfaces, which has significant advantages over traditional radiators and promises an alternative design technique for future spacecraft thermal control systems. All spacecraft rely on radiative surfaces to dissipate waste heat. These radiators have special coatings, typically with a low solar absorptivity and a high infrared-red emissivity, that are intended to optimize performance under the expected heat load and thermal sink environment. The dynamics of the heat loads and thermal environment make it a challenge to properly size the radiator and often require some means of regulating the heat rejection rate of the radiators in order to achieve proper thermal balance. Specialized thermal control coatings, which can passively or actively adjust their emissivity offer an attractive solution to these design challenges. Such systems would allow intelligent control of the rate of heat loss from a radiator in response to heat load and thermal environmental variations. Intelligent thermal control through variable emissivity systems is well suited for nano and pico spacecraft applications where large thermal fluctuations are expected due to the small thermal mass and limited electric resources. Presently there are three different types of vari-e technologies under development: Micro ElectroMechanical Systems (MEMS) louvers, Electrochromic devices, and Electrophoretic devices. This paper will describe several prototypes of micromachined (MEMS) louvers and experimental results for the emissivity variations measured on theses prototypes. It will further discuss possible actuation mechanisms and space reliability aspects for different designs. Finally, for comparison parametric evaluations of the thermal performances of the new vari-e technology and standard thermal control systems are presented in this paper.

Darrin, Ann Garrison↗

DOE OSTI2026

Power Electronic Development Challenges for High Power Density Integrated Electric Drive Applications

The ever-increasing demand for compact, efficient, and high-performance traction drive systems for transportation applications has accelerated the development of integrated electric drives. In these systems, the electric machine and inverter are integrated within a single housing, offering significant advantages in electrical performance, volume, weight, cost, and overall system efficiency. Despite these benefits, such high levels of integration introduce a new set of challenges, particularly in power electronic design and component selection. This article presents an in-depth investigation of a highly integrated electric drive architecture with an internal stator-mounted inverter, highlighting key design considerations and trade-offs aimed exclusively at maximizing system power density.Based on a comprehensive review of the literature, the power density of a voltage-source-inverter-driven electric drive is primarily governed by the volumetric contributions of the power modules, heat sinks, and DC-link capacitors. Accordingly, this work focuses on the optimization of these three critical components to enhance the inverter's overall power density. The proposed design achieves a power density of 100 kW/L, demonstrating the effectiveness of the presented approach for next-generation integrated electric drive systems.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2014

Space Evaporator Absorber Radiator (SEAR) for Thermal Storage on Manned Spacecraft

Future manned exploration spacecraft will need to operate in challenging thermal environments. State-of the- art technology for active thermal control relies on sublimating water ice and venting the vapor overboard in very hot environments. This approach can lead to large loss of water and a significant mass penalty for the spacecraft. This paper describes an innovative thermal control system that uses a Space Evaporator Absorber Radiator (SEAR) to control spacecraft temperatures in highly variable environments without venting water. SEAR uses heat pumping and energy storage by LiCl/water absorption to enable effective cooling during hot periods and regeneration during cool periods. The LiCl absorber technology has the potential to absorb over 800 kJ per kg of system mass, compared to phase change heat sink systems that typically achieve approx. 50 kJ/kg. The optimal system is based on a trade-off between the mass of water saved and extra power needed to regenerate the LiCl absorber. This paper describes analysis models and the predicted performance and optimize the size of the SEAR system, estimated size and mass of key components, and power requirements for regeneration. We also present a concept design for an ISS test package to demonstrate operation of a subscale system in zero gravity.

Izenson, Michael G.↗

NASA NTRS2023

Thermal Management System Modeling in the Heat Transport System Simulation (HeaTSSPy) Package

This paper describes the development of a thermal management system (TMS) concept design and analysis software package called Heat Transport System Simulation (HeaTSSPy). Built within Python using the OpenMDAO framework, HeaTSSPy can be used to size and optimize an active (using liquid/air heat exchangers) or passive (using finned heat sinks) TMS. The package makes use of modular TMS elements that allow for the creation of different system architectures and includes components such as heat sinks, heat exchangers, liquid pumps, fans, ducts, air inlets, air nozzles, and liquid pipes. Modeling methods for these components include a combination of physics-based analytical and empirical equations that relate component sizing criteria to system performance. The HeatSSPy heat sink methods are fully detailed within this paper, while the heat exchanger methods are described and referenced from previous work. This paper also uses high-fidelity simulation to validate two different methods of calculating thermal resistance using CFD results. Once the methods are fully described, the code is exercised to compare an active TMS with that of a passive TMS. Design criteria for this study include rejected heat, system altitude, Mach number, and ambient temperature. These criteria are used to develop a TMS system with estimated performance metrics such as weight, drag, and operational power. Results of this paper show the crossover point when a passive system begins to weigh more than an active system for a given heat rejection.

Thermal management system↗

DOE OSTI2020

Catalytic Enhancement of Inductively Heated Fe 3 O 4 Nanoparticles by Removal of Surface Ligands

Abstract Heat management in catalysis is limited by each material's heat transfer efficiencies, resulting in energy losses despite current thermal engineering strategies. In contrast, induction heating of magnetic nanoparticles (NPs) generates heat at the surface of the catalyst where the reaction occurs, reducing waste heat via dissipation. However, the synthesis of magnetic NPs with optimal heat generation requires interfacial ligands, such as oleic acid, which act as heat sinks. Surface treatments using tetramethylammonium hydroxide (TMAOH) or pyridine are used to remove these ligands before applications in hydrophilic media. In this study, Fe 3 O 4 NPs are surface treated to study the effect of induction heating on the catalytic oxidation of 1‐octanol. Whereas TMAOH was unsuccessful in removing oleic acid, pyridine treatment resulted in a roughly 2.5‐fold increase in heat generation and product yield. Therefore, efficient surfactant removal has profound implications in induction heating catalysis by increasing the heat transfer and available surface sites.

Moura, Natalia S.↗

DOE OSTI2022

Simulating a solar parabolic trough collector plant used for industrial process heat using an optimized operating scheme that utilizes flexible heat integration

This study focuses on the modeling and simulation of a novel design and operation of a solar industrial process heat (SIPH) plant that uses a parabolic trough collector system for generating process heat. The SIPH plant incorporates flexible heat integration (FHI) by having two options for heat sinks as well as a flexible collection temperature for the heat transfer fluid. Leveraging the degrees of freedom created by FHI allows an optimized operating scheme to be created which maximizes the solar heat delivered to the industrial processes. Yearly results for a 27 MW-t plant located in Salt Lake City, UT are simulated for a base case and a case utilizing optimized FHI. For the main process temperature case presented, FHI increases the total solar share by 13.0% and reduces the levelized cost of heat of the SIPH plant by 10.4% relative to the base case. Furthermore, three case study days are presented which highlight how FHI maximizes solar share, specifically during mornings, afternoons, and days with intermittent solar conditions. An environmental analysis is also performed showing that the SIPH plant can reduce harmful emissions by 15.4% for the base case and 17.4% for the FHI case compared to a plant that only utilizes a natural gas furnace for process heat. Overall, the work thoroughly explores an effective operating scheme for a SIPH plant, helping to make it more economical and environmentally beneficial.

14 SOLAR ENERGY↗

NASA NTRS2000

Towards Development of Microcalorimeter Arrays of Mo/Au Transition-Edge Sensors with Bismuth Absorbers

We report on our progress towards the development of arrays of X-ray microcalorimeters as candidates for the high resolution x-ray spectrometer on the Constellation-X mission. The microcalorimeter arrays (30 x 30) with appropriate pixel sizes (0.25 mm. x 0.25 mm) and high packing fractions (greater than 96%) are being developed. Each individual pixel has a 10 micron thick Bi X-ray absorber that is shaped like a mushroom to increase the packing fraction, and a Mo/Au proximity effect superconducting transition edge sensor (TES). These are deposited on a 0.25 or 0.5 micron thick silicon nitride membrane with slits to provide a controllable weak thermal link to the sink temperature. Studies are underway to model, test and optimize the TES pixel uniformity, critical current, heat capacity and the membrane thermal conductance in the array structure. Fabrication issues and procedures, and results of our efforts based on these optimizations will be provided.

Tralshawala, Nilesh↗

NASA NTRS2008

Magnetohydrodynamic Augmented Propulsion Experiment

Over the past several years, efforts have been under way to design and develop an operationally flexible research facility for investigating the use of cross-field MHD accelerators as a potential thrust augmentation device for thermal propulsion systems. The baseline configuration for this high-power experimental facility utilizes a 1.5-MWe multi-gas arc-heater as a thermal driver for a 2-MWe MHD accelerator, which resides in a large-bore 2-tesla electromagnet. A preliminary design study using NaK seeded nitrogen as the working fluid led to an externally diagonalized segmented MHD channel configuration based on an expendable heat-sink design concept. The current status report includes a review of engineering/design work and performance optimization analyses and summarizes component hardware fabrication and development efforts, preliminary testing results, and recent progress toward full-up assembly and testing

Litchford, Ron J.↗

DOE OSTI2024

The Monolithic Heat Pipe Microreactor Reference Plant Model

This work introduces a reference plant model for a generic monolithic heat-pipe-cooled microreactor. The model will serve as a springboard to develop future evaluation models in the licensing process of similar microreactor designs at the U.S. Nuclear Regulatory Commission. This model has been developed with the Comprehensive Reactor Analysis Bundle and its specifications are based on open literature publications for the eVinci TM design. BlueCRAB is the U.S. Nu- clear Regulatory Commission non-light-water reactor analysis system based on the Multiphysics Object-Oriented Simulation Environment framework, which can couple the Griffin, BISON, and Sockeye applications to resolve the various physics that are essential for the safety analysis of this type of reactor system. The core specifications includes tristructural isotropic fuel, graphite monolith, graphite reflectors, and drums composed of graphite and B 4 C. No moderator or burnable poison pins are used in the design. The fuel enrichment is reduced to control excess reactivity in the core. This core design is not optimized and only serves for testing purposes, since the primary objective of this work is to exercise the multiphysics coupling for this type of reactor system. A three dimensional (3D) core heterogeneous Griffin discrete ordinates (SN) transport model allows the precise calculation of the flux distribution and pin powers. Griffin transfers the power density distribution and obtains a temperature distribution to and from BISON. The BISON model com- putes the 3D core temperature distribution and is coupled to 876 Sockeye subapplications running a heat pipe model. This 3D conduction model is coupled to the various heat pipes via heat flux boundary conditions. The model includes a small gap between the heat pipe and the monolith. Convective heat transfer boundaries with either ambient temperature or condenser temperature as heat sinks are imposed at the model boundaries. The 2D Sockeye heat pipe model uses a vapor- only methodology, which provides the needed resolution for transient calculations and allows the determination of various heat pipe limits. This approach is superior to the superconductor model traditionally used in steady-state calculations. BlueCRAB computes steady-state power and temperature distributions that serve as the initial condition for a loss-of-heat-sink transient simulation. The steady-state results show significant peaking due to the position of the control drum, but this is a characteristic of the particular design used, which is not optimized at this stage. The transient results show the reactor power slowly stabilizing towards a 3% power level after the partial loss of secondary heat removal. Several recriticalities are observed due to cooling through the secondary system but the reactor is self-stabilizing and behaves as expected.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗