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Wide Bandgap Generation (WBGen): Developing the Future Wide Bandgap Power Electronics Engineering Workforce

This Final Technical Report (FTR) summarizes the work conducted at the Center for Power Electronics Systems (CPES) under the Wide-Bandgap Generation (WBGen) fellowship and traineeship program established by the Advanced Manufacturing and Technologies Office (AMMTO) of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) at Virginia Tech, which had as main objective to train the next generation of U.S. citizen power engineers with wide-bandgap (WBG) power semiconductor expertise, with the intent to aid in fulfilling the future workforce needs in this field. The latter was deemed of strategic importance given the fast-paced growth observed—and predicted—in the demand of this technical expertise, whose practitioners have become the enablers and executioners of the electrification transformation process that not just the U.S., but the whole world, is currently undergoing as it seeks for more effective and efficient ways to use energy. As such, the WBGen program set forth to achieve its educational goals, which in addition sought to broaden the range of WBG-based power electronics by conducting research and development on high-efficiency grid apparatus and high-efficiency electrical power systems, and to also enhance the power engineering curriculum by formalizing WBG-oriented design procedures replacing existent yet now obsolete design procedures developed for Silicon (Si) based power electronics. This effort led CPES to spearhead the development of a new major within The Bradley Electrical and Computer Engineering (ECE) Department at Virginia Tech, namely Electronic Power and Energy Systems (EPES), which coalesced power electronics and power systems courses to provide undergraduate students with a strong formation in the power engineering field, while creating a pipeline of graduate students that could pursue the WBG-based curriculum and conduct research at CPES. In all, in what is considered a true success, eight of the twenty WBGen fellows that graduated program were recruited from the ECE department undergraduate cohort. The traineeship emphasized as well, from its beginning, the partnership with industry and national laboratories, which took advantage of the successful industry consortium at CPES that has historically been formed by 80–90 power and energy companies working in close collaboration with the center. This gave WBGen fellows the accessibility and possibility to conduct internships at partner facilities during the summer months, focused solely on the evaluation, testing, and adoption of WBG devices, which were many times tightly related to their respective research work and plans. In addition, WBGen fellows conducted their main research work within the confines of research programs at CPES conducted with these industry partners, providing them with a unique opportunity to develop not just their technical expertise—while advancing their knowledge, but to also learn and practice a slew of skills needed for their professional growth. As such, the fellows tackled a variety of WBG-related research topics, from device reliability and capability aspects as well as packaging and integration, encompassing the use of advanced materials and new structures, current sharing challenges, and insulation systems, to advanced gate-drivers with integrated sensors and protection mechanisms and active current- and voltage-based control, to optimized layouts seeking to maximize the switching and power processing performance of these devices, to power processing solutions adopting Gallium-Nitride (GaN) and Silicon-Carbide (SiC) power semiconductors for a variety of applications; including radiation-hardened converters for space dc distribution systems, direct three-phase ac-to-ac power converters for aerospace systems, dc-ac inverters for automotive traction drives, high-frequency isolated dc-dc battery chargers also for heavy transportation systems, and medium-voltage dc-dc and dc-ac converters for distribution systems and future power grids. The WBGen program ultimately graduated a total of 20 power engineers, all experts on WBG-based power electronics, awarding 18 M.S. and 2 PhD degrees in the process. These fellows, all U.S. citizens, allowed CPES to increase the number of citizens students to 33 % at the peak of the program, as the traineeship made possible the recruitment of talent with more attractive graduate research assistantship (GRA) contracts. Unfortunately, the present U.S. citizen enrollment at CPES has declined back to historic levels—approximately 10 %, as the regular GRA rates are not competitive enough when compared with entry-level industry jobs. In all, WBGen fellows published a total of 7 peer-reviewed journal articles, 44 papers at international technical conferences, made 42 presentations at international technical conferences, and filed 4 invention disclosures and patent applications, which have since then been granted by the U.S. Patent and Trademark Office (USPTO). Their contribution to CPES, Virginia Tech, the United States, and the world, has been significant, and continues to yield results thanks to the exemplary career that the fellows have initiated at many of the partners of the program, which include Wolfspeed, Raytheon Technologies, Infineon, Lockheed Martin, Dominion Energy, Northrop Grumman, Rivian, Aerospace Corporation, Sandia National Laboratory, National Renewable Energy Laboratory, John Hopkins University, and Virginia Tech.

14 SOLAR ENERGY↗

DORMAN computer program (study 2.5). Volume 3: Original data bank listing

A number of analyses have been performed using the DORCA program for several NASA-funded Aerospace Corporation studies in the past few years. The data decks containing the input data for these analyses have been compiled and are submitted, under separate cover. A few of the data decks are full (basic) decks containing every data item and are used as reference decks in the data bank. The other data decks were obtained by differencing a full deck with respect to one of the reference decks. Using the DORMAN program, a full deck can be recreated from the modified deck and its reference deck when and if desired. The content and structure of the data bank are described. A description of each of these data decks is presented. Three of the cases that are included in this volume have become so widely recognized and accepted that additional descriptive material has been provided. The three cases are: Case 500 Costs, Case 506 Costs, and Case 403.

Stricker, L. T.↗

Absolute brightness temperature measurements at 2.1-mm wavelength

Absolute measurements of the brightness temperatures of the Sun, new Moon, Venus, Mars, Jupiter, Saturn, and Uranus, and of the flux density of DR21 at 2.1-mm wavelength are reported. Relative measurements at 3.5-mm wavelength are also preented which resolve the absolute calibration discrepancy between The University of Texas 16-ft radio telescope and the Aerospace Corporation 15-ft antenna. The use of the bright planets and DR21 as absolute calibration sources at millimeter wavelengths is discussed in the light of recent observations.

Ulich, B. L.↗

Measurement of energetic particle radiation at the synchronous altitude aboard ATS-6

The Aerospace Corporation energetic electron-proton spectrometer operating on ATS-6 is described. This experiment detects energetic electrons in four channels between 140 keV and greater than 3.9 MeV, measures energetic protons in five energy channels between 2.3 and 80 MeV and energetic alpha particles in three channels between 9.4 and 94 MeV. After more than a year of operation in orbit, the experiment continues to return excellent data on the behavior of energetic magnetospheric electrons as well as information regarding the fluxes of solar protons and alpha particles.

Paulikas, G. A.↗

Efficient searching and sorting applications using an associative array processor

The purpose of this paper is to describe a method of searching and sorting data by using some of the unique capabilities of an associative array processor. To understand the application, the associative array processor is described in detail. In particular, the content addressable memory and flip network are discussed because these two unique elements give the associative array processor the power to rapidly sort and search. A simple alphanumeric sorting example is explained in hardware and software terms. The hardware used to explain the application is the STARAN (Goodyear Aerospace Corporation) associative array processor. The software used is the APPLE (Array Processor Programming Language) programming language. Some applications of the array processor are discussed. This summary tries to differentiate between the techniques of the sequential machine and the associative array processor.

Pace, W.↗

Magnetohydrodynamic models of coronal transients in the meridional plane. II - Simulation of the coronal transient of 1973 August 21

A two-dimensional planar MHD model of solar atmospheric transient events is used to simulate the flare-associated events of August 21, 1973. This event, observed in H-alpha, He II 304 A, soft X-ray, and coronal white light, provided sufficient information (especially in the latter diagnostic) for an assessment to be made of the model's ability to simulate major features of an actual solar event. It was found that a thermodynamic input pulse based on data provided by the NASA Marshall Space Flight Center-Aerospace Corporation X-ray telescope (S-056) on Skylab was sufficient to produce the global geometry, shock and contact-surface velocities, excess mass contours, and energy budget which were, for the most part, observed by the High Altitude Observatory white-light coronagraph (S-052) on Skylab in the form of a forerunner and coronal transient.

Dryer, M.↗

The massively parallel processor

Future sensor systems will utilize massively parallel computing systems for rapid analysis of two-dimensional data. The Goddard Space Flight Center has an ongoing program to develop these systems. A single-instruction multiple data computer known as the Massively Parallel Processor (MPP) is being fabricated for NASA by the Goodyear Aerospace Corporation. This processor contains 16,384 processing elements arranged in a 128 x 128 array. The MPP will be capable of adding more than 6 billion 8-bit numbers per second. Multiplication of eight-bit numbers can occur at a rate of 2 billion per second. Delivery of the MPP to Goddard Space Flight Center is scheduled for 1983.

Schaefer, D. H.↗

Fiberglass composite blades for the 2 MW Mod-1 wind turbine generator

In mid-1979, NASA contracted with Kaman Aerospace Corporation for the design, manufacture, and ground testing of two 100 foot composite rotor blades intended for operation on the Mod-1 wind turbine. The Mod-1 blades have been completed and are currently stored at the Kaman facility. The design, tooling, fabrication, and testing phases which have been carried out to date, as well as testing still planned are described. Discussed are differences from the 150 foot blade which were introduced for cost and manufacturing improvement purposes. Also included is a description of the lightning protection system installed in the blades, and its development program. Actual costs and manhours expended for Blade No. 2 are provided as a base, along with a projection of costs for the blade in production. Finally, cost drivers are identified relative to future designs.

Batesole, W. R.↗

Aerospace spacecraft-charging guidelines document

A short summary document on spacecraft charging was prepared for use by engineers in the various Aerospace Corporation program offices that support Air Force Space Division programs. The magnetospheric charging environment at near-geosynchronous altitudes is outlined and the mechanisms of charging and discharging are discussed. Statistical results from the P78-2 (SCATHA) satellite engineering experiments are given. The document is intended to be a layman's source for charging information and for design guidance and criteria.

Fennell, J. F.↗

STACBEAM 2

An investigation being conducted by Astro Aerospace Corporation (Astro) for Jet Propulsion Laboratory in which efficient structures for geosynchronous spacecraft solar arrays are being developed is discussed. Recent developments in solar blanket technology, including the introduction of ultrathin (50 micrometer) silicon solar cells with conversion efficiencies approaching 15 percent, have resulted in a significant increase in blanket specific power. System specific power depends not only on blanket mass but also on the masses of the support structure and deployment mechanism. These masses must clearly be reduced, not only to minimize launch weight, but also to increase array natural frequency. The solar array system natural frequency should be kept high in order to reduce the demands on the attitude control system. This goal is approached by decreasing system mass, by increasing structural stiffness, and by partitioning the blanket. As a result of this work, a highly efficient structure for deploying a solar array was developed.

Adams, L. R.↗

A rotor optimization using regression analysis

The design and development of helicopter rotors is subject to the many design variables and their interactions that effect rotor operation. Until recently, selection of rotor design variables to achieve specified rotor operational qualities has been a costly, time consuming, repetitive task. For the past several years, Kaman Aerospace Corporation has successfully applied multiple linear regression analysis, coupled with optimization and sensitivity procedures, in the analytical design of rotor systems. It is concluded that approximating equations can be developed rapidly for a multiplicity of objective and constraint functions and optimizations can be performed in a rapid and cost effective manner; the number and/or range of design variables can be increased by expanding the data base and developing approximating functions to reflect the expanded design space; the order of the approximating equations can be expanded easily to improve correlation between analyzer results and the approximating equations; gradients of the approximating equations can be calculated easily and these gradients are smooth functions reducing the risk of numerical problems in the optimization; the use of approximating functions allows the problem to be started easily and rapidly from various initial designs to enhance the probability of finding a global optimum; and the approximating equations are independent of the analysis or optimization codes used.

Giansante, N.↗

The handling qualities and flight characteristics of the Grumman design 698 simulated twin-engine tilt Nacelle V/STOL aircraft

This paper describes three government-conducted, piloted flight simulations of the Grumman Design 698 vertical and short takeoff and landing (V/STOL) aircraft. Emphasis is placed on the aircraft's handling qualities as rated by various NASA, Navy, and Grumman Aerospace Corporating pilots with flight experience ranging from conventional takeoff and landing (CTOL) to V/STOL aircraft. Each successive simulation incorporated modifications to the aircraft in order to resolve the flight problems which were of most concern to the pilots in the previous simulation. The objective of the first simulation was to assess the basic handling qualities of the aircraft with the noncross-shafted propulsion system. The objective of the second simulation was to examine the effects of incorporating the cross-shafted propulsion system. The objective of the third simulation was to examine inoperative single-engine characteristics with and without cross-shafted engines.

Eskey, M. A.↗

Space Station - An innovative approach to manufacturing development

The development of the common modules for the planned dual-keel Space Station, which is a figure-eight configuration that requires the use of four common modules linked by six docking nodes in the center of the Station, is examined. The fabrication of the proposed common module designs, which are a four-barrel common module structure built using excess external tank barrel panels (Martin Marietta Michoud Aerospace), and a three-barrel design consisting of 2219 Al skins with a waffle-grid pattern machined on the outer surface (Boeing Aerospace Corporation) is described. The assistance provided by the NASA-Marshall Space Flight Center's Materials and Processes Laboratory, in particular the variable polarity plasma arc welding process, in the development of the common modules is discussed.

Sullivan, Kenneth W.↗

Nickel hydrogen low Earth orbit test program update and status

The current status of nickel-hydrogen (NiH2) testing ongong at NWSC, Crane In, and The Aerospace Corporation, El Segundo, Ca are described. The objective of this testing is to develop a database for NiH2 battery use in Low Earth Orbit (LEO) and support applications in Medium Altitude Orbit (MAO). Individual pressure vessel-type cells are being tested. A minimum of 200 cells (3.5 in diameter and 4.5 in diameter) are included in the test, from four U.S. vendors. As of this date (Nov. 18, 1986) approximately 60 cells have completed preliminary testing (acceptance, characterization, and environmental testing) and have gone into life cycling.

Badcock, C. C.↗

Sodium sulfur battery flight experiment definition study

Sodium-sulfur batteries were identified as the most likely successor to nickel-hydrogen batteries for space applications. One advantage of the Na/S battery system is that the usable specific energy is two to three times that of nickel-hydrogen batteries. This represents a significant launch cost savings or increased payload mass capabilities. Sodium-sulfur batteries support NASA OAST's proposed Civil Space Technology Initiative goal of a factor of two improvement in spacecraft power system performance, as well as the proposed Spacecraft 2000 initiative. The sodium-sulfur battery operates at between 300 and 400 C, using liquid sodium and sulfur/polysulfide electrodes and solid ceramic electrolyte. The transport of the electrode materials to the surface of the electrolyte is through wicking/capillary forces. These critical transport functions must be demonstrated under actual microgravity conditions before sodium-sulfur batteries can be confidently utilized in space. Ford Aerospace Corporation, under contract to NASA Lewis Research Center, is currently working on the sodium-sulfur battery space flight experiment definition study. The objective is to design the experiment that will demonstrate operation of the sodium-sulfur battery/cell in the space environment with particular emphasis on evaluation of microgravity effects. Experimental payload definitions were completed and preliminary designs of the experiment were defined.

Chang, Rebecca R.↗

Space power technology 21: Photovoltaics

The Space Power needs for the 21st Century and the program in photovoltaics needed to achieve it are discussed. Workshops were conducted in eight different power disciplines involving industry and other government agencies. The Photovoltaics Workshop was conducted at Aerospace Corporation in June 1987. The major findings and recommended program from this workshop are discussed. The major finding is that a survivable solar power capability is needed in photovoltaics for critical Department of Defense missions including Air Force and Strategic Defense Initiative. The tasks needed to realize this capability are described in technical, not financial, terms. The second finding is the need for lightweight, moderately survivable planar solar arrays. High efficiency thin III-V solar cells can meet some of these requirements. Higher efficiency, longer life solar cells are needed for application to both future planar and concentrator arrays with usable life up to 10 years. Increasing threats are also anticipated and means for avoiding prolonged exposure, retraction, maneuvering and autonomous operation are discussed.

Wise, Joseph↗

A generalized software executive for multidisciplinary computational structural dynamics

The objective of this presentation is to introduce the attendees to the DYSCO program. The emphasis will be on the features which make it multidisciplinary. DYSCO is a very general and versatile software program which couples and solves dynamic systems. It was initiated in the late 1970's in response to a helicopter analysis requirement. The system development, however, resulted in an executive which was completely separated from any particular area of technology, except that of second order ordinary differential equations. During the course of its development, it was funded by the Army Aviation Applied Technology Directorate, the Air Force Wright Aeronautical Laboratories, and by the Kaman Aerospace Corporation. It is completely written in FORTRAN and is operational on IBM and VAX computers.

Berman, Alex↗

Space telerobotic systems: Applications and concepts

The definition of a variety of assembly, servicing, and maintenance missions has led to the generation of a number of space telerobot concepts. The remote operation of a space telerobot is seen as a means to increase astronaut productivity. Dexterous manipulator arms are controlled from the Space Shuttle Orbiter cabin or a Space Station module. Concepts for the telerobotic work system have been developed by the Lyndon B. Johnson Space Center through contracts with the Grumman Aerospace Corporation and Marin Marietta Corporation. These studies defined a concept for a telerobot with extravehicular activity (EVA) astronaut equivalent capability that would be controlled from the Space Shuttle. An evolutionary development of the system is proposed as a means of incorporating technology advances. Early flight testing is seen as needed to address the uncertainties of robotic manipulation in space. Space robotics can be expected to spin off technology to terrestrial robots, particularly in hazardous and unstructured applications.

Jenkins, L.↗