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NASA NTRS2005

Reliability Assessment of Advanced Flip-clip Interconnect Electronic Package Assemblies under Extreme Cold Temperatures (-190 and -120 C)

Flip-chip interconnect electronic package boards have been assembled, underfilled, non-destructively evaluated and subsequently subjected to extreme temperature thermal cycling to assess the reliability of this advanced packaging interconnect technology for future deep space, long-term, extreme temperature missions. In this very preliminary study, the employed temperature range covers military specifications (-55 C to 100 C), extreme cold Martian (-120 C to 115 C) and asteroid Nereus (-180 C to 25 C) environments. The resistance of daisy-chained, flip-chip interconnects were measured at room temperature and at various intervals as a function of extreme temperature thermal cycling. Electrical resistance measurements are reported and the tests to date have not shown significant change in resistance as a function of extreme temperature thermal cycling. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work has been carried out to understand the reliability of flip-chip interconnect packages under extreme temperature applications (-190 C to 85 C) via continuously monitoring the daisy chain resistance. Adaptation of suitable diagnostic techniques to identify the failure mechanisms is in progress. This presentation will describe the experimental test results of flip-chip testing under extreme temperatures.

thermal cycling↗

NASA NTRS2011

Microcoil Spring Interconnects for Ceramic Grid Array Integrated Circuits

As integrated circuit miniaturization trends continue, they drive the need for smaller higher input/output (I/O) packages. Hermetically sealed ceramic area array parts are the package of choice by the space community for high reliability space flight electronic hardware. Unfortunately, the coefficient of thermal expansion mismatch between the ceramic area array package and the epoxy glass printed wiring board limits the life of the interconnecting solder joint. This work presents the results of an investigation by Marshall Space Flight Center into a method to increase the life of this second level interconnection by the use of compliant microcoil springs. The design of the spring and its attachment process are presented along with thermal cycling results of microcoil springs (MCS) compared with state-of-the-art ball and column interconnections. Vibration testing has been conducted on MCS and high lead column parts. Radio frequency simulation and measurements have been made and the MCS has been modeled and a stress analysis performed. Thermal cycling and vibration testing have shown MCS interconnects to be significantly more reliable than solder columns. Also, MCS interconnects are less prone to handling damage than solder columns. Future work that includes shock testing, incorporation into a digital signal processor board, and process evaluation of expansion from a 400 I/O device to a device with over 1,100 I/O is identified.

Strickland, S. M.↗

DOE OSTI2026

Regional inertia dynamics of U.S. interconnections: An event-based measurement approach

Power grid inertia plays a vital role in frequency stability following large disturbances, yet its distribution across the U.S. grid is highly uneven. While interconnection-wide inertia benchmarks are useful, they can mask regional variability driven by resource mix, network coupling, and geographic separation. This paper extends event-driven inertia estimation to the regional scale using field measurements from the Frequency Monitoring Network (FNET/GridEye). Starting from balancing authority and independent system operator footprints, candidate regions are refined using a composite coherency score that combines frequency-trajectory shape similarity, timing spread, and lead/lag behavior to ensure dynamic consistency. A filtered sliding difference method (FSDM) is then used to construct regional frequency trajectories, detect disturbance onset, and compute robust regional rate-of-change of frequency (RoCoF). Regional, local, and interconnection inertia are estimated by combining RoCoF with event power imbalance, and additional indicators (regional-to-system inertia ratio and inertial-support arrival time) quantify regional-to-interconnection coupling and relative regional contributions. The method is demonstrated on eleven regions across the Eastern Interconnection (EI) and the Western Electricity Coordinating Council (WECC), with the Electric Reliability Council of Texas (ERCOT) used for validation. In ERCOT, estimates compared against energy management system (EMS) values achieve a mean absolute percentage error of 17.94%. WECC exhibits consistently shorter inertial-support arrival times (0.15–0.3 s) than EI (0.7–1.1 s), highlighting contrasting coupling and disturbance-propagation behavior. Overall, the results reveal pronounced spatial heterogeneity in inertia and coupling, underscoring the value of regional monitoring for both operational decision-making and long-term system planning.

Disturbance events↗

DOE OSTI2024

Inertia Estimation and Trend Analysis of the United States Power Grid Interconnections

The transition from conventional to modern power systems is causing an increase in integration of inverter-based resources (IBRs). This generally leads to a decrease in total system inertia, which in-turn increases the system’s rate-of-change-of-frequency (RoCoF) during disturbances. This poses a threat to the frequency stability of the system and may falsely trigger protective devices. To monitor system status and plan for integrating renewable energy sources like photovoltaic, wind, and energy storage systems, a realistic study of inertia estimation and analysis in the United States (US) over the past decade is needed. This paper uses field-measured phasor measurement unit (PMU) data collected throughout the US from 2013 to 2023 via the Frequency Monitoring Network (FNET/GridEye) operated by the University of Tennessee, Knoxville (UTK) and Oak Ridge National Laboratory (ORNL). The collected PMU frequency data is utilized to estimate the system inertia of the three US interconnections: Eastern, Western, and Texas. Various RoCoF time windows are investigated for estimating the inertia of each interconnection by maximizing the correlation coefficient between the measured RoCoF and power mismatch. The resulting inertia trends over the past decade show approximately a 6% decline in inertia in the Eastern interconnection, a 15% decline in inertia in the Western interconnection, and a 16% increase in inertia in Texas. Key insights into how inertia is changing amidst the complex energy landscape are extracted using the fuel mix trend data. This provides valuable information for future energy strategies and planning.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Beyond the Bridge: Contention-Based Covert and Side Channel Attacks on Multi-GPU Interconnect

Recently, high-speed interconnects like NVLink have become a standard integration in modern multi-GPU systems, serving as a crucial bridge between CPUs and GPUs. This study highlights the vulnerability of multi-GPU systems to covert and side-channel attacks arising from congestion on these interconnects. An adversary, operating without special permissions, can extract private information about a victim's activities by monitoring NVLink congestion. Specifically, we leverage this insight to develop a covert channel attack across two GPUs, achieving a respectable bandwidth of 33 Kbps. Additionally, we introduce a side-channel attack that allows attackers to fingerprint applications on a remote GPU by probing the shared NVLink interconnect. We underscore the urgent nature of the threats posed by these attacks and advocate for heightened awareness within both industry and academia to implement multi-GPU interconnects with enhanced security measures.

Zhang, Yicheng↗

DOE OSTI2025

IM3 Projected U.S. Western Interconnection Grid Stress Dataset

This dataset provides projected grid stress and reliability results (including all model inputs and outputs from GO WEST and TEP) for Integrated Multisector, Multiscale Modeling (IM3) Phase 2 simulations across eight different scenarios for the U.S. Western Interconnection through 2055. The scenarios include combinations of two Shared Socioeconomic Pathways (SSP3 and SSP5) with four high-resolution climate projections specific to the United States from a set of Thermodynamic Global Warming (TGW) simulations. These climate projections include "hotter" and "cooler" variants for two Representative Concentration Pathways (RCP4.5 and RCP8.5). The resulting eight simulations are: rcp45cooler_ssp3 rcp45cooler_ssp5 rcp45hotter_ssp3 rcp45hotter_ssp5 rcp85cooler_ssp3 rcp85cooler_ssp5 rcp85hotter_ssp3 rcp85hotter_ssp5 GO WEST is an open-source power grid modeling framework for the U.S. Western Interconnection, which allows users to tailor the model depending on their research study and science questions. It covers 28 balancing authorities (BAs) and 12 states in U.S. Western Interconnection. GO WEST allows users to select different number of nodes and come up with a simplified network by utilizing 10,000 nodal topology of the U.S. Western Interconnection (ACTIVSg10k). Users can select different number of nodes, mathematical formulations (linear programming vs. mixed-integer linear programming), transmission line limit scaling factors, and hurdle rate scaling factors. GO WEST offers a unit commitment and economic dispatch (UC/ED) module to simulate grid operations on an hourly scale. In this sense, users can calibrate and validate their model versions by comparing model outputs to historical datasets. TEP is an open-source transmission capacity expansion model, built on the GO WEST framework. It utilizes linear programming to optimize transmission capacity addition investment on existing lines within the GO WEST framework. The TEP model only increases the thermal capacity of existing transmission lines and does not add new lines to the system, which leaves the topology preserved. In order to use TEP model, users need to create scenarios with the GO WEST framework. Please refer to README file for a detailed description of the dataset including individual files and references.

Capacity Expansion Model↗

NASA NTRS1977

Transequatorial loops interconnecting McMath regions 12472 and 12474

The paper reviews the life history of one transequatorial loop in a system observed in soft X-rays for at least 1.5 days and which interconnected a newly born active region with an old region. The birth of the selected loop is discussed along with properties of the interconnected active regions, sharpening and brightening of the loop, decay of the loop system, and physical relations between the interconnected regions. It is concluded that: (1) the loop was most probably born via reconnection of magnetic-field lines extending from the two active regions toward the equator, which occurred later than 33 hr after the younger region was born; (2) the fully developed interconnection was composed of several loops, all of which appeared to be rooted in a spotless magnetic hill of preceding northern polarity but were spread over two separate spotty regions of southern polarity in the magnetically complex new region; (3) the loop electron temperature increased from 2.1 million to 3.1 million K in one to three hours when the loop system brightened; and (4) the loops became twisted during the brightening, possibly due to their rise in the corona while remaining rooted in moving magnetic features in the younger region.

Svestka, Z.↗

NASA NTRS1981

Transient brightenings of interconnecting loops. II - Dynamics of the brightened loops

Three different kinds of dynamic events related to interconnecting loops observed in soft X-rays aboard Skylab are discussed: (1) a newly born transequatorial loop that was either emerging from subphotospheric layers or gradually filled in with hot plasma; (2) large-scale twists of interconnecting loops which never relax, and often only form after the loop brightenings, and (3) three events where the loop that later interconnected two active regions had been visible long before one of the interconnecting regions was born. Several impacts this observation might have upon the understanding of the process of flux emergence are suggested.

Svestka, Z.↗

NASA NTRS1982

Design solutions for the solar cell interconnect fatigue fracture problem

Mechanical fatigue of solar cell interconnects is a major failure mechanism in photovoltaic arrays. A comprehensive approach to the reliability design of interconnects, together with extensive design data for the fatigue properties of copper interconnects, has been published. This paper extends the previous work, developing failure prediction (fatigue) data for additional interconnect material choices, including aluminum and a variety of copper-Invar and copper-steel claddings. An improved global fatigue function is used to model the probability-of-failure statistics of each material as a function of level and number of cycles of applied strain. Life-cycle economic analyses are used to evaluate the relative merits of each material choce. The copper-Invar clad composites demonstrate superior performance over pure copper. Aluminum results are disappointing.

Mon, G. R.↗

NASA NTRS1987

Implementation of optical interconnections for VLSI

This paper reports on the progress in implementing optical interconnections for VLSI. Four areas are covered: (1) the holographic optical element (HOE), (2) the laser sources, (3) the detectors and associated circuits forming an optically addressed gate, and (4) interconnection experiments in which five gates are actuated from one source. A laser scanner system with a resolution of 12 x 20 microns has been utilized to generate the HOEs. Diffraction efficiency of the HOE and diffracted spot size have been measured. Stock lasers have been modified with a high-frequency package for interconnect experiments, and buried heterostructure fabrication techniques have been pursued. Measurements have been made on the fabricated photodetectors to determine dark current, responsivity, and response time. The optical gates and the overall chip have been driven successfully with an input light beam, as well as with the optical signal interconnected through the one to five holograms.

Wu, Wennie H.↗

NASA NTRS1990

Optical interconnections and networks; Proceedings of the Meeting, The Hague, Netherlands, Mar. 14, 15, 1990

The conference presents papers on interconnections, clock distribution, neural networks, and components and materials. Particular attention is given to a comparison of optical and electrical data interconnections at the board and backplane levels, a wafer-level optical interconnection network layout, an analysis and simulation of photonic switch networks, and the integration of picosecond GaAs photoconductive devices with silicon circuits for optical clocking and interconnects. Consideration is also given to the optical implementation of neural networks, invariance in an optoelectronic implementation of neural networks, and the recording of reversible patterns in polymer lightguides.

Bartelt, Hartmut↗

NASA NTRS2005

Process Developed for Generating Ceramic Interconnects With Low Sintering Temperatures for Solid Oxide Fuel Cells

Solid oxide fuel cells (SOFCs) have been considered as premium future power generation devices because they have demonstrated high energy-conversion efficiency, high power density, and extremely low pollution, and have the flexibility of using hydrocarbon fuel. The Solid-State Energy Conversion Alliance (SECA) initiative, supported by the U.S. Department of Energy and private industries, is leading the development and commercialization of SOFCs for low-cost stationary and automotive markets. The targeted power density for the initiative is rather low, so that the SECA SOFC can be operated at a relatively low temperature (approx. 700 C) and inexpensive metallic interconnects can be utilized in the SOFC stack. As only NASA can, the agency is investigating SOFCs for aerospace applications. Considerable high power density is required for the applications. As a result, the NASA SOFC will be operated at a high temperature (approx. 900 C) and ceramic interconnects will be employed. Lanthanum chromite-based materials have emerged as a leading candidate for the ceramic interconnects. The interconnects are expected to co-sinter with zirconia electrolyte to mitigate the interface electric resistance and to simplify the processing procedure. Lanthanum chromites made by the traditional method are sintered at 1500 C or above. They react with zirconia electrolytes (which typically sinter between 1300 and 1400 C) at the sintering temperature of lanthanum chromites. It has been envisioned that lanthanum chromites with lower sintering temperatures can be co-fired with zirconia electrolyte. Nonstoichiometric lanthanum chromites can be sintered at lower temperatures, but they are unstable and react with zirconia electrolyte during co-sintering. NASA Glenn Research Center s Ceramics Branch investigated a glycine nitrate process to generate fine powder of the lanthanum-chromite-based materials. By simultaneously doping calcium on the lanthanum site, and cobalt and aluminum on the chromium site, we could sinter the materials below 1400 C. The doping concentrations were adjusted so that the thermal expansion coefficient matched that of the zirconia electrolyte. Also, the investigation was focused on stoichiometric compositions so that the materials would have better stability. Co-sintering and chemical compatibility with zirconia electrolyte were examined by X-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy (line scanning and dot map). The results showed that the materials bond well, but do not react, with zirconia electrolyte. The electric conductivity of the materials measured at 900 C in air was about 20 S/cm.

Zhong, Zhi-Min↗

NASA NTRS2004

Electrode and interconnect for miniature fuel cells using direct methanol feed

An improved system for interconnects in a fuel cell. In one embodiment, the membranes are located in parallel with one another, and current flow between them is facilitated by interconnects. In another embodiment, all of the current flow is through the interconnects which are located on the membranes. The interconnects are located between two electrodes.

Narayanan, Sekharipuram R.↗

NASA NTRS2009

Free-Space Optical Interconnect Employing VCSEL Diodes

Sensor signal processing is widely used on aircraft and spacecraft. The scheme employs multiple input/output nodes for data acquisition and CPU (central processing unit) nodes for data processing. To connect 110 nodes and CPU nodes, scalable interconnections such as backplanes are desired because the number of nodes depends on requirements of each mission. An optical backplane consisting of vertical-cavity surface-emitting lasers (VCSELs), VCSEL drivers, photodetectors, and transimpedance amplifiers is the preferred approach since it can handle several hundred megabits per second data throughput.The next generation of satellite-borne systems will require transceivers and processors that can handle several Gb/s of data. Optical interconnects have been praised for both their speed and functionality with hopes that light can relieve the electrical bottleneck predicted for the near future. Optoelectronic interconnects provide a factor of ten improvement over electrical interconnects.

Simons, Rainee N.↗

DOE OSTI2025

Degrees of Rate Control in Interconnected Reaction Networks

Overall reactions in interconnected networks exhibit net, forward, and reverse rates that are governed by both constitutive elementary steps in the pathway of interest and branching elementary steps that lead to alternative products. Accordingly, steps in branching pathways exhibit negative net, forward, and reverse degrees of rate control, as they reduce reaction flux to the desired product. We here contextualize the forward and reverse degrees of rate control in terms of kinetic resistances (inverse of rates) and leverage the additive nature of kinetic resistance to decouple kinetic driving forces contributed by constitutive elementary steps and branching points (nodal species) in interconnected networks. Regardless of the network connectivity, forward and reverse degrees of rate control are shown to converge at equilibrium. Away from equilibrium, we identify two critical features of interconnected networks: stoichiometric regularity─condition where all stoichiometric numbers are unity─and pathway symmetry around nodal species─condition where branching pathways share the same rate constants, stoichiometry, and species concentrations/activities─that result in (i) equal forward, reverse, and consequently net degrees of rate control and (ii) forward and reverse degrees of rate control that exhibit constant offsets, respectively, across all extents of reaction. Furthermore, our discourse further provides a mathematical description for the influence of stoichiometric irregularity and pathway asymmetry on forward and reverse degrees of rate control. Altogether, the presented work details the effects of network (inter)connectivity and stoichiometry on reaction kinetics and, in doing so, establishes general protocols for capturing these effects as additive terms in the formulation of forward and reverse degrees of rate control.

10 SYNTHETIC FUELS↗

DOE OSTI2026

Energy Infrastructure Futures: A Multiscale Evaluation of Projected Power Plant Siting Across the Western Interconnection

The US Western Interconnection is facing unprecedented challenges in the form of less predictable peak demand, increasingly diverse generating resources, and fast-growing loads due to the onset of artificial intelligence, hyperscale computing, and electrification. Projecting where future generation may be developed is critical to maintaining a robust and resilient electric grid under this mounting uncertainty and variability. Using an integrated multisectoral, multiscale modeling framework that links a human-Earth systems model, an hourly load model, a geospatial power plant siting model, and an hourly grid operations model, we evaluate the power plant landscape evolution under eight alternative futures between 2020 and 2055. These futures represent a wide but plausible range of atmospheric conditions, emissions constraints, and economic, technological, and population growth assumptions. We find that local-level development can vary substantially both by generation type and capacity buildout across these futures. Specific regions of the Western Interconnection are projected to see large amounts of capacity development regardless of the future scenario. We additionally determine that projected power plant locations are more heavily influenced by the cost to interconnect to the electric grid than the locational energy value.

Mongird, Kendall↗

DOE OSTI2026

Towards dislocation-driven quantum interconnects

A central problem in the deployment of quantum technologies is the realization of robust architectures for quantum interconnects. We propose to engineer interconnects in semiconductors and insulators by patterning spin qubits at dislocations, thus forming quasi one-dimensional lines of entangled point defects. To gain insight into the feasibility and control of dislocation-driven interconnects, we investigate the optical cycle and coherence properties of nitrogen-vacancy (NV) centers in diamond, in proximity of dislocations, using a combination of advanced first-principles calculations. We show that one can engineer spin defects with properties similar to those of their bulk counterparts, including charge stability and a favorable optical cycle, and that NV centers close to dislocations have much improved coherence properties. Finally, we predict optically detected magnetic resonance spectra that may facilitate the experimental identification of specific defect configurations. Our results provide a theoretical foundation for the engineering of one-dimensional arrays of spin defects in the solid state.

Materials science↗

DOE OSTI2025

Comparative Analysis of Inter-Area Oscillations in the US Eastern and Western Interconnections

This paper presents a comparative analysis of interarea oscillations in the US Eastern and Western Interconnections using frequency disturbance data collected from the advanced wide-area Frequency Monitoring Network (FNET/GridEye), enabling us to investigate and compare the oscillation characteristics of both regions. The study analyzes the statistical data from the two interconnections, including total oscillation events, average dominant frequencies, damping ratios, and maximum amplitudes. We also explore the impact of seasonal and daily variations on oscillation occurrences and the influence of different grid topologies and operational practices. The results provide insights into both interconnections' stability and control characteristics, offering valuable information for power system operators to enhance grid stability and oscillation suppression measures.

Fu, Hao [University of Tennessee, Knoxville (UTK)]↗