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At least 469 records · Page 26

Thermal Assessment and In-Situ Monitoring of Insulated Gate Bipolar Transistors in Power Electronic Modules: Preprint

Insulated gate bipolar transistor (IGBT) power modules are devices commonly used for switching of high voltages and currents. Usage and environmental conditions can cause these power modules to degrade over time, and this gradual process may eventually lead to catastrophic failure of the device. This degradation process may cause some early performance symptoms related to the state of health of the power module, making it possible to detect reliability degradation of the IGBT module. Testing can be used to accelerate this process, permitting a rapid determination of whether specific declines in device reliability can be characterized. In this study, thermal cycling was conducted on multiple power modules simultaneously in order to assess the effect of thermal cycling on the degradation of the power module. In-situ monitoring of temperature was performed from inside each power module using high temperature thermocouples. Device imaging and characterization was performed along with temperature data analysis, to assess failure modes and mechanisms within the power modules. While the experiment was aimed to assess the potential damage effects of thermal cycling on die attach, results indicated that wirebond degradation was the life limiting failure mechanism.

33 ADVANCED PROPULSION SYSTEMS↗

P1-Marx Modulator for the ILC

A first generation prototype, P1, Marx-topology klystron modulator has been developed at the SLAC National Accelerator Laboratory for the International Linear Collider (ILC) project. It is envisioned as a lower cost, smaller footprint, and higher reliability alternative to the present, bouncer-topology, baseline design. The application requires 120 kV (+/-0.5%), 140 A, 1.6 ms pulses at a rate of 5 Hz. The Marx constructs the high voltage pulse by combining, in series, a number of lower voltage cells. The Marx employs solid state elements; IGBTs and diodes, to control the charge, discharge and isolation of the cells. Active compensation of the output is used to achieve the voltage regulation while minimizing the stored energy. The P1-Marx has been integrated into a test stand with a 10 MW L-band klystron, where each is undergoing life testing. A review of the P1-Marx design and its operational history in the L-band test stand are presented.

43 PARTICLE ACCELERATORS↗

Improving Solar PV Degradation Prediction Certainty: PREDICTS2 (Final Technical Report)

The rate and type of in-service PV performance degradation vary for different module designs, vintages, and operating climates. The current IEC 61215 module qualification testing standard can be used to identify design and manufacturing flaws that may lead to early life failures, but it was not intended to accurately predict degradation rates in the first 5 to 10 years of a PV plant’s lifetime, nor long-term performance, under varied operating conditions. Correlations between accelerated aging data and real-world degradation data are needed to better predict wear-out degradation in response to environmental stressors, such as elevated temperature, temperature cycling, moisture, wind load, and solar radiation. The PREDICTS2 project aged 36 pristine-condition ‘spare’ modules from a commercial PV power plant in the U.S. Southwest using the IEC 61215 and Qualification Plus (Qual Plus) testing standards. The study is unique in its ability to compare performance degradation data for fielded modules operating outdoors for 6 years in a commercial plant environmental with degradation data for modules of the same make, model and vintage that have been aged artificially in an indoor laboratory. Changes in individual module current-voltage (I-V) curve data were measured before and after the artificial aging process and compared to I-V curve data for the fielded modules. This project advanced the industry’s understanding of how environmental stressors affect performance degradation and established relationships between degradation mechanisms and changes to module electrical parameters and power loss. Improved certainty in degradation rates is expected to be the greatest source of LCOE reduction resulting from this project. Reducing the spread in the degradation rate probability distribution lowers project risk, which translates to lower project financing costs.

14 SOLAR ENERGY↗

SU-E-T-269: Differential Hazard Analysis For Conventional And New Linac Acceptance Testing Procedures

Purpose: New techniques and materials have recently been developed to expedite the conventional Linac Acceptance Testing Procedure (ATP). The new ATP method uses the Electronic Portal Imaging Device (EPID) for data collection and is presented separately. This new procedure is meant to be more efficient then conventional methods. While not clinically implemented yet, a prospective risk assessment is warranted for any new techniques. The purpose of this work is to investigate the risks and establish the pros and cons between the conventional approach and the new ATP method. Methods: ATP tests that were modified and performed with the EPID were analyzed. Five domain experts (Medical Physicists) comprised the core analysis team. Ranking scales were adopted from previous publications related to TG 100. The number of failure pathways for each ATP test procedure were compared as well as the number of risk priority numbers (RPN’s) greater than 100 were compared. Results: There were fewer failure pathways with the new ATP compared to the conventional, 262 and 556, respectively. There were fewer RPN’s > 100 in the new ATP compared to the conventional, 41 and 115. Failure pathways and RPN’s > 100 for individual ATP tests on average were 2 and 3.5 times higher in the conventional ATP compared to the new, respectively. The pixel sensitivity map of the EPID was identified as a key hazard to the new ATP procedure with an RPN of 288 for verifying beam parameters. Conclusion: The significant decrease in failure pathways and RPN’s >100 for the new ATP mitigates the possibilities of a catastrophic error occurring. The Pixel Sensitivity Map determining the response and inherent characteristics of the EPID is crucial as all data and hence results are dependent on that process. Grant from Varian Medical Systems Inc.

60 APPLIED LIFE SCIENCES↗

TU-B-304-02: Quantitative FMEA of TG-142

Although published in 2009, the AAPM TG-142 report on accelerator quality assurance still proves a challenge for full clinical implementation. The choice of methodologies to satisfy TG-142 requirements is critical to a successful application. Understanding the philosophy of TG-142 can help in creating an institution-specific QA practice that is both efficient and effective. The concept of maintaining commissioned beam profiles is still found confusing. The physicist must also consider technologies not covered by TG-142 (i.e. arc therapy techniques). On the horizon is TG-198 report on implementing TG-142. Although the community still lacks a final TG-100 report, performing a failure-mode -and-effects analysis and statistical process control analysis to determine the institution-specific clinical impact of each TG-142 test may be useful for identifying trends for pro-active surveillance. Learning Objectives: To better understand the confusing and controversial aspects of TG-142. To understand what is still missing from TG-142 and how to account for these tests in clinical practice To describe which QA tests in TG-142 yield the largest potential clinical result if not discovered.

60 APPLIED LIFE SCIENCES↗

Screening and evaluation of biomass upgrading strategies for sustainable transportation fuel production with biomass-derived volatile fatty acids

Biomass conversion to fuels and chemicals is crucial to decarbonization, but choosing an advantageous upgrading pathway out of many options is challenging. Rigorously evaluating all candidate pathways (process simulation, product property testing) requires a prohibitive amount of research effort; even simple upgrading schemes have hundreds of possible permutations. We present a method enabling high-throughput screening by approximating upgrading unit operations and drop-in compatibility of products (e.g., fuel properties) and apply it to volatile fatty acid (VFA) conversion to liquid transportation fuels via a MATLAB script, VFA Upgrading to Liquid Transportation fUels Refinery Estimation (VULTURE). VULTURE selects upgrading configurations that maximize fuel blend bio-derived content. We validate VULTURE's approximations through surrogate fuel property testing and process simulation. Techno-economic and life cycle analyses suggest that VFA upgrading processes down-selected by VULTURE are profitable and have low carbon intensities, demonstrating the potential for the strategy to accelerate process development timelines at decreased costs.

09 BIOMASS FUELS↗

Non linear viscoelasticity applied for the study of durability of polymer matrix composites

A methodology is described for the durability analysis of polymer matrix composites, based on nonlinear viscoelasticity theory. The durability analysis is performed on the basis of a certain number of tests carried out on limited and, if possible, short time scale by the use of accelerating factors. The method was applied to thermomatrix composites under uniaxial and biaxial loadings, showing satisfactory agreement between the life-time predictions and the published data on real-time behavior.

Cardon, A.↗

Influence of Microstructure on the Fatigue Crack Growth of A516 in Hydrogen

Some day hydrogen may be used as a viable energy storage and transport medium within the United States. Hydrogen gas may be used to dilute and extend our present methane supply as a blend or may even be used in its pure elemental form as a primary fuel. Independent of the methods of production, storage, and distribution, the interaction of hydrogen with its containment material will play an integral role in the success of a hydrogen energy program. Presently, the selection of hydrogen containment materials can be made such that the material will remain reasonably free from environmental degradation; however, costly alloying additions are required. Unfortunately, high alloy steels are economically prohibitive when large-scale hydrogen energy storage, transmission, and conversion systems are desired. Therefore, in order to implement such hydrogen energy systems in the future, existing low-cost materials must be improved via mechanical, thermal, or thermo-mechanical processing methods or new low-cost materials which are compatible with hydrogen must be developed. Originally, low strength, low alloy steels at room temperature were thought to be immune to hydrogen gas embrittlement, since no sustained load crack growth is observed. However, results of Clark in HY8O and Nelson in SAE 1020 have shown that the fatigue crack growth rate can be greatly accelerated in the presence of hydrogen gas. In recent results reported by Louthan and Mucci, the smooth bar fatigue life of an A1068 pipeline steel was reduced up to a factor of ten when the tests were performed in a 13.8 MPa hydrogen environment. These results suggest that the selection of material for structures designed to operate in hydrogen under cyclic loads must include consideration of hydrogen/metal fatigue interaction. Although the hydrogen/metal fatigue interaction can be severe in low strength low alloy steels, the degree of degradation may be altered by the underlying ferrous microstructure. At present, no correlation between microstructure and degree of hydrogen susceptibility exists for low strength steels. However, in high strength steels, susceptibility to hydrogen embrittlement has been shown to be strongly sensitive to the metallurgical microstructure. In addition, compositional effects and grain size can 703 Some day hydrogen may be used as a viable energy storage and transport medium within the United States. Hydrogen gas may be used to dilute and extend our present methane supply as a blend or may even be used in its pure elemental form as a primary fuel. Independent of the methods of production, storage, and distribution, the interaction of hydrogen with its containment material will play an integral role in the success of a hydrogen energy program. Presently, the selection of hydrogen containment materials can be made such that the material will remain reasonably free from environmental degradation; however, costly alloying additions are required. Unfortunately, high alloy steels are economically prohibitive when large-scale hydrogen energy storage, transmission, and conversion systems are desired. Therefore, in order to implement such hydrogen energy systems in the future, existing low-cost materials must be improved via mechanical, thermal, or thermo-mechanical processing methods or new low-cost materials which are compatible with hydrogen must be developed.

Wachob, Harry F.↗

A Dispersion-Strengthened Low-Density Niobium Alloy and Its Elevated Temperature Mechanical Performance

In response to the elevated-temperature and weight-reduction demands of modern aerospace applications, a novel oxide-dispersion-strengthened low-density niobium alloy (LDNb-ODS) was fabricated using laser powder bed fusion (L-PBF). To overcome powder procurement barriers, L-PBF feedstock was produced by blending commercial Nb521, Ti64, and Cr powder with Y2O3 nanoparticles via resonant acoustic mixing. Following L-PBF and a 1400°C vacuum heat treatment, the alloy achieved a density of 6.73 g/cc and a fine mean grain size of 4.62 µm stabilized by uniform ~30 nm yttria dispersoids. Microstructural analysis revealed a chemically inhomogeneous build with lack-of-fusion defects and a titanium (Ti) shift from a nominal 31.5 wt% in the starting powder blend to 24.8 wt% in the printed part due to preferential Ti loss during printing. Elevated-temperature tensile testing demonstrated that LDNb-ODS maintained a superior specific yield strength of 60-85 MPa/(g/cc) up to 800°C, outperforming nickel-based alloys Ni625, Ni230, and GRX-810. Between 870°C and 950°C, its specific strength surpassed both Ni718 and Ni625. In rapid stress-rupture testing at 1093°C and 20.7 MPa, uncoated LDNb-ODS survived 21.4 hours (a tenfold increase over legacy C-103) while an R512E silicide coating extended rupture life to 84.8 hours, confirming that oxidation accelerates low-stress failure. These findings demonstrate that additive manufacturing of LDNb-ODS provides a viable, lightweight alternative to nickel-based superalloys for high-temperature (>850°C) aerospace components.

Low Density Niobium Alloy↗

SU-F-T-496: An Investigation of Two Novel Devices for Testing Linac Clearance During CT Simulation

Purpose: This work’s objective is to determine the efficacy of two newly patented devices termed the Mor-O rings, Mark1 and Mark2, developed to predict collisions between the patient and a linac at the time of CT simulation. Methods: Mark1: A ring with an inner radius equal to the distance between the isocenter and the nearest portion of a linac head(diso) was made. This is mounted to a stand that allows vertical repositioning. The ring is placed around the patient on the CT table and aligned with isocenter. The patient is moved through the ring. If the ring touches the patient, a collision is predicted. To test this device, predicted collisions were marked on a phantom. The phantom was then repositioned on the linac table where the collisions were verified. Mark2: An arc with the radius diso was created with a re-locatable half-linac head wire-frame. The Mark2 is positioned in the same way as the Mark1 but can additionally mimic couch and gantry angulations. The Mark2 was tested with a volunteer using multiple couch, gantry and isocenter positions. The volunteer was then repositioned on the linac table to verify the angles of collisions. Results: Mark1: One isocenter out of ten showed negative clearance (0.9mm) on the linac table. All other collisions were predicted with 1 to 36mm of additional clearance. Mark2: All collisions were prevented with an additional 1.3 to 14.8 degrees of clearance. Conclusion: The Mark1 prototype is able to predict all collisions when no couch angulation is used. This device takes less than a minute to setup and is simple to use. The Mark2, when testing beam geometries used for noncoplanar SBRT, was able to prevent all collisions with 1.3 to 14.8 degrees additional clearance. Improvements in construction for both devices could increase accuracy and usability. Andrew Morrow owns Morrow Physics, LLC and Brian Massingill owns Spur Physics, LLC. We are both listed on the patent for the devices investigated in this work (patent 9220922). Our current employer, Baylor Scott and White, is also on the patent.

60 APPLIED LIFE SCIENCES↗

Long-term module testing at Wyle Laboratories

Results are presented for a current set of accelerated long-term endurance tests on crystalline silicon module of various constructions. Cell materials include single crystal, semicrystal, EFG ribbon, and dendritic web ribbon. The latest data set is for the equivalent of 20-year life and showed satisfactory performance.

Otth, D. H.↗

An implantable biomechanical energy harvester for animal monitoring devices

Insufficient service life and the resulting need for battery replacements have been a great challenge for implantable electronic devices. This is particularly true for animal tracking applications, because recapturing animals is often unlikely once they are released to the wild. To tackle this problem, we developed a biomechanical energy harvester that uses a Macro Fiber Composite™ (MFC) piezoelectric beam to harvest the mechanical energy from animals’ body bending movements as the power source for implantable and wearable devices. Prototypes of an underwater acoustic transmitter using this technology were subdermally implanted into juvenile white sturgeon and their energy harvesting performance was evaluated through the device’s transmissions. Additionally, the fish successfully recovered from the implantation surgery and freely swam inside a tank. The transmitter prototypes in the fish continually transmitted signals for a period up to 5 weeks. A benchtop test setup was also created to emulate the fish’s body bending, estimate the device’s energy harvesting performance in the live fish, and perform accelerated fatigue testing of the energy harvester by applying test parameters learned from a video study of the fish’s body movement and behavior characteristics. The gradual depolarization of the piezoelectric ceramic material in the MFC under cyclic mechanical loading was the main limiting factor for the life span of the energy harvester. Pathways for improvement are proposed to achieve long-term efficacy of powering implantable and wearable electronic devices.

42 ENGINEERING↗

Structural Benchmark Creep Testing for the Advanced Stirling Convertor Heater Head

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for use on long duration Science missions such as lunar applications, Mars rovers, and deep space missions. For the inherent long life times required, a structurally significant design limit for the heater head component of the ASRG Advanced Stirling Convertor (ASC) is creep deformation induced at low stress levels and high temperatures. Demonstrating proof of adequate margins on creep deformation and rupture for the operating conditions and the MarM-247 material of construction is a challenge that the NASA Glenn Research Center is addressing. The combined analytical and experimental program ensures integrity and high reliability of the heater head for its 17-year design life. The life assessment approach starts with an extensive series of uniaxial creep tests on thin MarM-247 specimens that comprise the same chemistry, microstructure, and heat treatment processing as the heater head itself. This effort addresses a scarcity of openly available creep properties for the material as well as for the virtual absence of understanding of the effect on creep properties due to very thin walls, fine grains, low stress levels, and high-temperature fabrication steps. The approach continues with a considerable analytical effort, both deterministically to evaluate the median creep life using nonlinear finite element analysis, and probabilistically to calculate the heater head s reliability to a higher degree. Finally, the approach includes a substantial structural benchmark creep testing activity to calibrate and validate the analytical work. This last element provides high fidelity testing of prototypical heater head test articles; the testing includes the relevant material issues and the essential multiaxial stress state, and applies prototypical and accelerated temperature profiles for timely results in a highly controlled laboratory environment. This paper focuses on the last element and presents a preliminary methodology for creep rate prediction, the experimental methods, test challenges, and results from benchmark testing of a trial MarM-247 heater head test article. The results compare favorably with the analytical strain predictions. A description of other test findings is provided, and recommendations for future test procedures are suggested. The manuscript concludes with describing the potential impact of the heater head creep life assessment and benchmark testing effort on the ASC program.

Krause, David L.↗

Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power (abstract)

Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a GPHS in AMTEC powered outer planet probes requires the device to be constructed to tolerate T greater than 1150K, as well as exposure to Na(sub (g)), and Na(sub (liq)) on the high pressure side. The temperatures involved make critical high strength and chemical resistance to Na containing Na(sub 2)O. Selection among materials which can be worked should not be driven by ease of fabricability, as high temperature stability is the critical issue. These concepts drive the selection of Mo alloys for Na(sub (liq)) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable NB or Ta alloys, are less soluble in Na(sub (liq)) containing dissolved Na(sub 2)O, are workable compared to W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.

AMTEC thermal to electric conversion↗

Component Selection, Accelerated Testing, and Improved Modeling of AMTEC Systems for Space Power

Alkali metal thermal to electric converter (AMTEC) designs for space power are numerous, but the selection of materials for construction of long-lived AMTEC devices has been limited to electrodes, current collectors, and the solid electrolyte. AMTEC devices with lifetimes greater than 5 years require careful selection and life testing of all hot-side components. The likely selection of a remote condensed design for initial flight test and probable use with a radioisotope heat source in AMTEC powered planet probes requires the device to be constructed to tolerate operating T greater than 1150K, as well as exposure to Na (g) , and Na (liq) on the high pressure side. The temperatures involved make the characterization of high strength and chemical resistance to Na containing Na 2 O critical. Selection among materials which can be worked should not be driven by ease of fabricablity, as high temperature stability is the critical issue. These concepts drive the selecton of Mo alloys for Na (liq) containment in AMTEC cells for T to 1150K operation, as they are significantly stronger than comparable Nb or Ta alloys, are less soluble in Na (liq) containing dissolved Na 2 O, are workable compared with W alloys (which might be used for certain components), and are ductile at the T greater than 500K of proposed AMTEC modules in space applications.

AMTEC↗

Low Cycle Fatigue and Creep-Fatigue Behavior of Alloy 617 at High Temperature

Alloy 617 is the leading candidate material for an intermediate heat exchanger (IHX) application of the Very High Temperature Nuclear Reactor (VHTR), expected to have an outlet temperature as high as 950 degrees C. Acceptance of Alloy 617 in Section III of the ASME Code for nuclear construction requires a detailed understanding of the creep-fatigue behavior. Initial creep-fatigue work on Alloy 617 suggests a more dominant role of environment with increasing temperature and/or hold times evidenced through changes in creep-fatigue crack growth mechanism/s and failure life. Continuous cycle fatigue and creep-fatigue testing of Alloy 617 was conducted at 950 degrees C and 0.3% and 0.6% total strain in air to simulate damage modes expected in a VHTR application. Continuous cycle specimens exhibited transgranular cracking. Intergranular cracking was observed in the creep-fatigue specimens, although evidence of grain boundary cavitation was not observed. Despite the absence of grain boundary cavitation to accelerate crack propagation, the addition of a hold time at peak tensile strain was detrimental to cycle life. This suggests that creepfatigue interaction may occur by a different mechanism or that the environment may be partially responsible for accelerating failure.

36 MATERIALS SCIENCE↗

SU-E-T-433: Calibration Accuracy in Mailed High-Resolution 3D Dosimetry Service for SRS/SBRT QA

Purpose: SRS/SBRT combines hypofractionation with excellent dose distributions. However, extremely steep gradients across the target along with dose escalation, if not administered accurately, may lead to serious complications, recurrences, or even fatalities. Existing commercial QA products either lack adequate spatial resolution or the 3D aspect. By contrast, the new CrystalBall™ mailed high-resolution 3D dosimetry service removes the above limitations while reducing the overall workload on medical physics staff. The exposed dosimeters, which change optical density in proportion to local dose, are sent back to the manufacturer (MGS Research Inc., Madison, CT) for sub-millimeter-resolution laser-CT scanning and QA data analysis. QA report is returned electronically within 24 hours. The purpose of this study was to evaluate the dose calibration accuracy in this system. Methods: Two spherical CrystalBall™ polymer gel dosimeters from the same batch, 166 mm diameter, with embedded 3D image registration markers, were mounted in a special phantom designed for reproducible positioning. For full end to end testing, the optical guidance array was mounted onto the phantom and a CT was taken. Two separate Rapid Arc SRS plans were designed. Varian Medical Systems optical guidance system was used to position the phantom and the SRS treatment plans were delivered to the two spheres on Varian's Trilogy Accelerator. Exposed dosimeters were mailed back to the manufacturer for laser CT scanning and analysis. Results: For each plan, 3D gamma passing rate was 100% for 2%/2mm distance-to-agreement criteria above 50% isodose level. The two calibration curves, generated using volumetric dose and optical density data, showed excellent mutual agreement (max difference 2.2%, median difference 0.75%). Conclusion: The clinical utility of new CrystalBall™ mailed QA service for SRS/SBRT and high accuracy of dose calibration have been validated. The workflow associated with the use of the CrystalBall™ in clinical setting was found to be minimal. The presenting author is the founder of and has an ownership in MGS Research Inc which manufactures the CrystalBall system for 3D dosimetry.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Three Year Aging of Prototype Flight Laser at 10 Khz and 1 Ns Pulses with External Frequency Doubler for the Icesat-2 Mission

We present the results of three year life-aging of a specially designed prototype flight source laser operating at 1064 nm, 10 kHz, 1ns, 15W average power and external frequency doubler. The Fibertek-designed, slightly pressurized air, enclosed-container source laser operated at 1064 nm in active Q-switching mode. The external frequency doubler was set in a clean room at a normal air pressure. The goal of the experiment was to measure degradation modes at 1064 and 532 nm discreetly. The external frequency doubler consisted of a Lithium triborate, LiB3O5, crystal operated at non-critical phase-matching. Due to 1064 nm diagnostic needs, the amount of fundamental frequency power available for doubling was 13.7W. The power generated at 532 nm was between 8.5W and 10W, depending on the level of stress and degradation. The life-aging consisted of double stress-step operation for doubler crystal, at 0.35 J/cm2 for almost 1 year, corresponding to normal conditions, and then at 0.93 J/cm2 for the rest of the experiment, corresponding to accelerated testing. We observed no degradation at the first step and linear degradation at the second step. The linear degradation at the second stress-step was related to doubler crystal output surface changes and linked to laser-assisted contamination. We discuss degradation model and estimate the expected lifetime for the flight laser at 532 nm. This work was done within the laser testing for NASA's Ice, Cloud, and land Elevation Satellite-2 (ICESat-2) LIDAR at Goddard Space Flight Center in Greenbelt, MD with the goal of 1 trillion shots lifetime.

Frequency Doubling↗