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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Nuclear Forensics

Nuclear forensics is a key part of the nuclear security strategy for the United States and the international community. The NACS Division is central to the leadership role that LLNL has had in nuclear forensics over the past 25 years. Our current nuclear forensic program includes conducting R&D on provenance and attribution signatures, collaborating with international partners, training the next generation of nuclear forensic experts, developing test materials for verification and validation exercises, and providing expert advice to national and international policy makers. Key to our success in these areas has been the strong and continuing involvement in nuclear forensic casework obtained through law enforcement and intelligence channels as well as our outstanding analytical capabilities. NACS must continue to conduct forward-thinking R&D in nuclear forensics that supports operational programs and addresses intelligence gaps. To maintain leadership in nuclear forensics, we must attract, develop, and retain the best talent. The NNSA has a central leadership role in developing educational initiatives for nuclear forensics. In concert with the Glenn T. Seaborg Institute, the NACS Division will continue to participate in all nuclear forensic educational initiatives (undergraduate, graduate, postdoctoral) and incorporate LLNL’s D&I vision into its student and postdoc recruitment efforts. We will continue to build formal relationships with key academic partners and institutions with active and emerging nuclear forensic research interests. We will also strengthen relationships with NNSA DNN and SSAA funded university consortia (e.g. NSSC, ACE, CNEC, CVT, ETI, MTV), helping them conduct research of interest and relevance to nuclear forensics, while at the same time evaluating and recruiting promising talent from these programs.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

LANL Meteorology Program Self-Assessment 2025 Update

The LANL Meteorological (Met) Program has been subject to several external reviews over the past 19 years. The DOE Meteorological Coordinating Council (DMCC) conducted an initial Met Program Site Assist Visit (SAV) in August 2006 (DMCC 2006). A follow-up SAV in August 2015 assessed progress (DMCC 2015), and in June 2023, the DOE Meteorological Subcommittee (DMSC), successor to the DMCC, conducted a second follow-up SAV (DMSC 2023), in which the Met Program was evaluated relative to the following 8 high-level questions: • What is the state of the meteorological services provided to its customers? • What is the quality of meteorological data provided to its customers and is it adequate and available to meet all customer needs? • What is the quality of atmospheric transport and diffusion modeling provided to its customers and is it applicable to complex wind flow patterns at LANL? • Are the current and future meteorological service customers being serviced appropriately? • Are there adequate human resources to meet present and future program customer needs and are they being appropriately leveraged? • Are existing instrumentation, facilities, and systems adequate to meet present and future customer needs? • Are LANL meteorological services conducted in an efficient, cost-effective manner? • Is meteorological data used to ensure safety & health of LANL personnel? More specific evaluations were performed relative to 23 performance objectives extracted from the ANSI/ANS-3.11- 2024 national standard and 14 separate performance objectives associated with consequence assessment and atmospheric transport and diffusion modeling in the consequence assessment element of DOE G 151.1-1B. In 2023, the DMSC SAV Team also reviewed the status of each of the 18 remaining recommendations from its 2015 SAV. Based on this review, DMSC stated in its Exit Briefing that the LANL meteorological program has gotten much stronger and more robust since 2015 and now represents one of the better managed programs within the DOE complex.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Impacts of Thawing Permafrost on Residential Infrastructure: Results and Resources

Permafrost underlies approximately 20% of the landmass in the Northern Hemisphere. Inevitably human infrastructure has been and will be built on permafrost; however, due to climate change, the permafrost in many regions has begun to thaw. Using past reports and surveys as guidance, a survey was conducted to track the effects of permafrost thaw on housing infrastructure in the community of Point Lay, Alaska. The Cold Climate Housing Research Center, Inc. and the National Renewable Energy Lab conducted a literature review and interviews to document community issues from thawing permafrost and identify potential mitigation strategies for existing and new infrastructure. Researchers also identified strategies for individual homeowners to inspect their foundations for current issues or anticipate future ones. This poster will cover the results from the survey on the effects of permafrost thawing to Point Lay and include permafrost basics, common concerns from thawing permafrost, steps to identify permafrost sites and visible signs of permafrost degradation, and potential mitigation strategies that may be beneficial to Alaskans and increase resilience in the Arctic.

Alaska↗
DOE OSTI2024

UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers

The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Screen printable copper pastes for silicon solar cells

The current work demonstrates the successful metallization of a PERC silicon solar cell with screen-printable copper (Cu) paste that is sintered at elevated temperature in air atmosphere. The existing state of the art in Silicon (Si) solar cell metallization is silver (Ag) paste; Cu cost is 1/100th the cost of Ag and has a comparable conductivity. However, Cu undergoes rapid oxidation at elevated temperatures and the high diffusion of Cu into Si restricts its usage in the metallization of silicon solar cells. In this paper, a Cu paste containing a proprietary mixture of antioxidant additives and diffusion inhibitors was used to make front gridlines on PERC cells. The Cu-printed cells were fired in an IR belt furnace with a peak temperature of 576°C in air atmosphere. The solar cells discussed here reached an efficiency of 19%, which is 88% of the efficiency measured for a commercial Ag-printed cell. The working devices were further characterized using STEM, EDX, ToF-SIMS and long-term suns-V oc studies demonstrating an absence of Cu diffusion. Furthermore, thermally stressing the Cu-printed solar cells yielded a reduction of less than 1.9% of the initial pseudo fill factor (pFF) after 1000 hours at 200°C. Here, the shunt resistance of cells monitored over 3 years remained within 2.5% of its initial value, which demonstrates the effectiveness of the Cu diffusion barrier.

14 SOLAR ENERGY↗
DOE OSTI2020

A comprehensive conductivity model for drift and micro-tearing modes

The parallel electrical conductivity is a crucial parameter in the study of the linear stability of drift-modes like the micro-tearing mode (MTM). The conductivity enters by closing the electromagnetic tearing layer equations. Recent progress in the understanding of the pedestal suggests that the MTM could play an important role in its structure and evolution. For this reason, we revisit and improve previous model conductivities. This parameter is generally derived from the linearized drift kinetic equation. In the past literature, it has been computed using either simplified collision operators or neglecting the spatial dependence away from the rational surface. Here, a fully consistent expression for the conductivity that would accurately model the pedestal has not been available. By applying a novel variational procedure and with the full Fokker Plank collision operator, including electron–electron collisions, we compute a closed expression for the parallel electrical conductivity in the form of a rational function.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Metal-Complex Inks for Lower Cost and Improved Passivation for Silicon Photovoltaic Metallization

This contribution introduces the silicon PV community to screen-printable metal-complex inks that potentially will reduce Ag usage in Si PV metallization to one-quarter and costs to one-third that of traditional particle-based pastes while also improving passivation. Metal-complex inks are formulated using a Tollen's reaction to produce inks with a high percentage of diamminesilver (I) cations (22 wt %) in a solution of acetate and formate anions. When printed and dried labile ammonia ligands evaporate, leaving behind silver cations which, when reduced by formate anions and acetic acid, plate out silver and silver acetate. When annealed to just 300 degrees C a dense metallic silver film forms with excellent conductivity, and adhesion to silicon. When compared to traditional particle-based screen-printing pastes, the metal-complex inks are much denser, have higher conductivity, use less Ag, and are a fraction of the cost. Importantly, the inks anneal from 90 - 450 degrees C allowing for better passivation schemes than fired SiNx. This contribution highlights first experiments on the improved passivation of metallized poly-Si/SiO2 passivated contacts using metal-complex, Ag inks compared with particle-based, fired pastes.

metal-complex ink↗
DOE OSTI2025

Financial Analysis of the High Flow Experiment conducted at the Glen Canyon Dam during Water Year 2023

The Glen Canyon Dam (GCD) is a Colorado River Storage Project (CRSP) power resource that is a component of the Salt Lake City Area Integrated Projects (SLCA/IP). The 2016 record of decision (ROD) for the GCD long-term experimental and management plan (LTEMP) final Environmental Impact Statement (EIS) specified criteria for GCD monthly water releases, daily and hourly operating limits, and experimental releases. This report examines the financial implications of the high flow experiment (HFE) conducted at GCD during the spring of Water Year (WY) 2023 as required by the LTEMP HFE Protocol. This report is part of a series of reports that describe the financial costs of LTEMP experimental releases since the 2016 ROD was adopted in January 2017. Previous reports analyzed the impact of several past HFEs and Bug Flow Experiments. This report focuses on the HFE conducted in April 2023. For this experimental release, financial costs of approximately $1.33 million were incurred because the HFE required sustained water releases exceeding the power plant’s maximum turbine flow rate. In addition, during the experiment, operators were not allowed to shape GCD power production, either to follow Firm Electric Service (FES) customer day-ahead energy deliveries or to respond to market prices. This study identifies the main factors contributing to the HFE costs and examines the interdependencies among these factors. It applies an integrated set of tools to estimate Western Area Power Administration (WAPA) financial impacts by simulating GCD under two types of cases; namely, (1) a “With Experiment” case that mimics the operations that actually occurred and (2) a “Without Experiment” case that simulates operations under the assumption that the HFE did not occur. The “With Experiment” case mimics operations during the HFE and the entire month the HFE occurred. It complies with LTEMP hourly and daily operating criteria. The “Without Experiment” case assumes that the HFE did not occur. The monthly water release volume is assumed to be identical under both cases. The Colorado River Storage Project Python-based model (CRiSPPy) model was the main modeling tool used to simulate the dispatch of the GCD hydropower plant and associated water releases from Lake Powell. In the modeling process, the research team used extensive data sets and historical information on SLCA/IP power plant characteristics, hydrologic conditions, and WAPA’s power purchases and sales prices. In addition to estimating the financial impact of the HFE, the team used the CRiSPPy model to gain insights into the interplay among ROD operating criteria, exceptions made to criteria to accommodate the HFE, and WAPA operating practices.

13 HYDRO ENERGY↗
DOE OSTI2022

DETAIL Component Scaling and Methodology Comparison

The purpose of this study was to develop a process to convert input signals from one facility into another by reflecting geometric and environmental settings. The Dynamic Energy Transport and Integration Laboratory (DETAIL) is a research facility in development. Its aim is to emulate the daily interactions among power production industry systems and receive real-time data from those systems as inputs. To convert signals and ensure that the temporal sequences and magnitudes reflect laboratory settings, the ability to scale and project data is essential. To demonstrate this ability, Dynamical System Scaling (DSS) and Hierarchical Two-Tiered Scaling (H2TS) (methodologies that enable systems to scale and project or extrapolate data sets to desired environments while conserving the observed behavior based on first principles) were applied to DETAIL’s thermocline thermal storage system in the Thermal Energy Distribution System (TEDS) facility and solid-oxide electrolysis cell in the High Temperature Hydrogen Electrolysis (HTHE) facility. Both thermocline and electrolysis cell systems were successfully scaled, and test cases were conducted to generate a doubly accelerated energy charge and discharge in reference to past experimental data from the facilities. The research results represented a case for the thermocline system that required signals to be accelerated without altering the stored energy. To enhance the quality of the accelerated data, error propagation analyses were conducted on DSS post-processing terms to determine the consequences of raw-data-associated errors.

08 HYDROGEN↗
DOE OSTI2024

Metal-Complex Inks for Lower Cost and Improved Passivation for Silicon Photovoltaic Metallization

This contribution introduces the silicon PV community to screen-printable metal-complex inks that potentially will reduce Ag usage in Si PV metallization to one-quarter and costs to one-third that of traditional particle-based pastes while also improving passivation. Metal-complex inks are formulated using a Tollen’s reaction to produce inks with a high percentage of diamminesilver (I) cations (22 wt %) in a solution of acetate and formate anions. When printed and dried, labile ammonia ligands evaporate, leaving behind silver cations which, when reduced by formate anions and acetic acid, plate out silver and silver acetate. When annealed to just 300 °C a dense metallic silver film forms with excellent conductivity, and adhesion to silicon. When compared to traditional particle-based screen-printing pastes, the metal-complex inks are much denser, have higher conductivity, use less Ag, and are a fraction of the cost. Importantly, the inks anneal from 90 – 450 °C allowing for improved passivation schemes compared with fired SiNx. This contribution highlights first experiments on the improved passivation of metallized poly-Si/SiO2 passivated contacts using metal-complex Ag inks.

Young, David L. (ORCID:0000000340970493)↗
DOE OSTI2023

A Progress Report for a 44-month Aging Study on Nitroplasticizer (NP) Stability – Summary of KF and TGA Results

In the past few years, a 44-month long aging experiment was conducted under various aging conditions. The properties of aged nitroplasticizer (NP) samples were analyzed using Fourier transform infrared spectroscopy, Karl Fischer (KF) titration, thermogravimetric analysis (TGA), liquid chromatography tandem quadrupole time of flight mass spectrometry, and ion chromatography. In this progress report, complete KF and TGA results are reported and discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Progress Report for a 44-month Aging Study on Nitroplasticizer (NP) Stability - Summary of DFT and FTIR Results

In the past few years, a 44-month long aging experiment was conducted under various aging conditions. The properties of aged nitroplasticizer (NP) samples were analyzed using Fourier transform infrared spectroscopy, Karl Fischer (KF) titration, thermogravimetric analysis (TGA), liquid chromatography tandem quadrupole time of flight mass spectrometry (LC/QTOF), and ion chromatography (IC). In this progress report, some FTIR results are documented and discussed. On the theoretical front, density functional theory (DFT) calculations were carried out. Some DFT results are discussed as well.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Updates on the Wake Potential Calculations for the Electron-ion Collider with ECHO3D

ECHO3D has been used for calculating the geometric impedance and short-range wakefields for several EIC (Electron-Ion Collider) beamline vacuum components in the past few years. This note summarizes the wake potential calculations conducted in 2023 with ECHO3D for components from both the hadron storage ring (HSR) and the electron storage ring (ESR). For the HSR, calculations have been carried out for the polarimeter, the beam screen with pump slots and the bellow with pump ports. For the ESR, the short-range wake potential for the flange weld as well as various designs of the storage ring cavity have been calculated.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

DOE Deep Energy Retrofit Cost Survey

A survey was conducted by the Lawrence Berkeley National Laboratory on deep energy retrofit (DER) market drivers, opportunities, and challenges. The survey was part a research study sponsored by the U.S. Department of Energy to gather information on the costs of DER from home performance contractors and stakeholders. Cost data was gathered from DER projects that use a comprehensive, whole-home approach to drastically reduce energy use and improve performance. DER projects often aim at reducing energy use by 50% or more. In addition, these projects can improve home comfort and potentially benefiting occupant health. Yet, market adoption of DER has been limited. Major limiting factors include complex projects, high costs, perceived risks, extensive disruption, and unfamiliar work scopes to some contractors. In order to better understand what motivates and deters DER projects in today’s market, a survey was conducted to gather this information, and to learn about promising approaches and technologies from the industry perspective. Past surveys on homeowners and home energy performance professionals have studied the motivations and barriers of energy efficiency retrofits. Two surveys of home energy performance professionals were conducted in recent years. The Resources for the Future (RFF) Home Energy Audit and Retrofit Survey was conducted in 2011 by recruiting energy auditors and retrofit installers through members of Efficiency First and Building Performance Institute (BPI) accredited contractors. The survey asked about the business and services that respondents provide, how often homeowners follow their recommendations to retrofit their homes, and the respondents’ opinion on barriers faced by the industry. The survey found that not enough homeowners know about energy audits, but more importantly, it is the high cost of retrofits compared to low energy prices that is responsible for few energy audits and retrofits being completed. The RESNET Deep Retrofit Industry Stakeholder Survey was conducted shortly after launching of the EnergySmart Home Performance Team program. The EnergySmart Team program involves a formal agreement among allied contractors who are engaged in high performance retrofits. Using this allied team approach, teams can pool their expertise and provide each other with customer referrals. The survey asked EnergySmart Team members and outside stakeholders on questions about market and technical barriers in performing home energy retrofits. Survey respondents identified lack of consumer awareness and lack of affordable financing for consumers as the leading market barriers to home energy retrofits. In their written comments, many survey respondents also echoed that the high costs of retrofit compared to low energy prices is a market barrier. Respondents found “certain housing characteristics that prevent effective retrofit” and “energy analysis software inaccuracy or limitations” are the two leading technical barriers. Their choices for technical barriers were reflective of the energy rater/auditor role played by the majority (78%) of the survey respondents. In comparison to past surveys, this work aimed to gather inputs from a broader segment of the home performance industry to identify the opportunities and barriers faced by DERs from all perspectives. The survey asks for project costs to help breakdown the high costs of DERs. This survey is also motivated by a need to better understand the role of DERs in reducing energy use by the residential sectors and meeting climate goals. The survey is designed towards obtaining more substantive inputs from survey respondents by encouraging written comments, rather than setting the goal to reach a large number of respondents. We took this approach because DER is currently still a niche market, so it is more valuable to gather in-depth inputs from individuals who are performing this work rather than getting to the masses.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

iBLAST: Incremental BLAST of new sequences via automated e-value correction

Search results from local alignment search tools use statistical scores that are sensitive to the size of the database to report the quality of the result. For example, NCBI BLAST reports the best matches using similarity scores and expect values (i.e., e-values) calculated against the database size. Given the astronomical growth in genomics data throughout a genomic research investigation, sequence databases grow as new sequences are continuously being added to these databases. As a consequence, the results (e.g., best hits) and associated statistics (e.g., e-values) for a specific set of queries may change over the course of a genomic investigation. Thus, to update the results of a previously conducted BLAST search to find the best matches on an updated database, scientists must currently rerun the BLAST search against the entire updated database, which translates into irrecoverable and, in turn, wasted execution time, money, and computational resources. To address this issue, we devise a novel and efficient method to redeem past BLAST searches by introducing iBLAST. iBLAST leverages previous BLAST search results to conduct the same query search but only on the incremental (i.e., newly added) part of the database, recomputes the associated critical statistics such as e-values, and combines these results to produce updated search results. Our experimental results and fidelity analyses show that iBLAST delivers search results that are identical to NCBI BLAST at a substantially reduced computational cost, i.e., iBLAST performs (1 + δ )/ δ times faster than NCBI BLAST, where δ represents the fraction of database growth. We then present three different use cases to demonstrate that iBLAST can enable efficient biological discovery at a much faster speed with a substantially reduced computational cost.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Thermal Stimulation and Injectivity Testing at Raft River, ID EGS Site

The Raft River geothermal field is the site of an innovative Department of Energy Enhanced Geothermal System (EGS) project to determine the viability of using combined thermal and hydraulic stimulation techniques to improve energy production. Well RRG-9 is currently undergoing a stimulation program using injectate from the US Geothermal Raft River Power Plant and cold water from a cooling tower make-up water well. The stimulation began on 13 June 2013 with injection from the power plant at a temperature of about 39 °C and a pressure of 275 psig. Next, two positive displacement plunger type pumps were used to increase the injection pressure and flow rate for about one month. The highest rate achieved was 258 gpm at a pressure of 741 psig. During this time, fluid from the cooler water well was injected for about 2 weeks at various pressures. Then, the pumps were removed and plant injection resumed on 25 September. Plant injection will continue until the spring of 2014, when a high pressure hydraulic stimulation will be conducted. A series of seismic monitoring stations deployed around the well are providing data on seismic events occurring at the site. Over the past year, 51 microseismic events have been recorded, all less than Magnitude 1. During injection, several diagnostic tests were conducted to gain a better understanding of the well and reservoir. A step-rate test was performed on 22 August to measure the in-situ stress and aid in modeling in-situ fractures. A tracer was injected into the well on 9 September. No tracer was detected in adjacent production wells after several months. A second borehole televiewer survey was conducted for comparison to pre-stimulation images. Here, a third borehole televiewer survey is planned after the high pressure stimulation. Injection test data is evaluated in real time. A modified Hall plot analysis indicates the effective permeability is increasing. The injectivity index supports the results of the modified Hall plot analysis. As the thermal stimulation has continued, the injectivity index has consistently followed an upward trend from 0.1 gpm/psi to 0.53 gpm/psi.

enhanced geothermal systems↗
DOE OSTI2023

Shock-induced transformation of nitinol shape memory alloy: Effect of stress state on transformation

Due to its numerous practical applications and intriguing phase transformation behavior, shape memory alloys (SMAs) have garnered significant research and development interests. In the past, most studies on the mechanical behavior of SMAs have been conducted under uniaxial stress loadings. Limited research on SMAs under shock loading has not provided conclusive results regarding their transformation behavior and transformation stress under such loading. Additionally, there is a lack of comprehensive understanding regarding the effects of different stress states on transformation behavior. The main objectives of this study are to address these issues. To achieve these objectives, a series of shock wave experiments were designed and conducted. Additionally, quasi-static and dynamic uniaxial stress experiments were carried out to establish a baseline for comparison. The results revealed that the transformation stress under dynamic uniaxial strain shock loading was approximately 1.92 GPa in contrast to 0.5 GPa (quasi-static) to 0.8 GPa (dynamic) observed in uniaxial stress loading. The transformation behavior exhibited noticeable rate sensitivity for both types of loading. There appeared to be a critical strain rate above which the austenite phase was driven to a metastable state. This estimated critical axial strain rate along the loading direction was approximately 2 × 10 3 /s–4 × 10 3 /s for uniaxial stress loading and approximately 2 × 10 6 /s for uniaxial strain loading. The apparent high transformation stress for uniaxial strain loading can likely be attributed to a combination of high-pressure confinement and high strain rate. Furthermore, determining their relative contributions remains an open issue.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Encapsulation Residual Stress and Ferrite Loss in Inductive Coil Assemblies

As inductive wireless charging reaches higher power levels, thermal management and mechanical durability become more critical. To address these concerns, past works have demonstrated the benefit of encapsulating coil assemblies in thermally conductive materials. However, due to the sensitivity of the MnZn ferrites commonly used in coil assemblies to mechanical stress, care must be taken to avoid creating large stresses in the ferrite that cause higher hysteresis loss. The stress formation in the encapsulant curing process is overviewed and modeled and an experiment is performed to demonstrate the effect in a small-scale coil assembly. Finally, the effect is shown in the reduced coil-coil efficiency of a first generation high power inductive power transfer prototype using a stiff epoxy compared to better performance in a second prototype using a softer thermally-conductive silicone encapsulant.

Foote, Andrew↗