Nanocomposite Magnetic Technology for High Frequency MW Scale Power Conversion
The purpose of this project was to demonstrate the use of advanced magnetic materials in a medium voltage DC-DC converter for photovoltaic applications. The lead, alloy development team met project development milestones targeting a low loss material (<20 W/kg at 10kHzT), alloy resistivity (>150μΩcm amorphous phase resistivity), evaluation of the operational lifetime of the material (continuous operation above 155C), and the performance metric (power ratio >100) for a new class of Co-rich alloys with tunable permeability. Material manufacturability was demonstrated in continuously casting over 5 kg batches of 1’’ width, 18μm thickness (less than 80-120% deviation), amorphous ribbon, and processing including field and strain annealing as well as rolling both Fe and Co based alloys to less the 15μm was achieved. Parallel technology to markets efforts found that while a more compact and more efficient converter, which reduces the balance of plant cost, would enjoy a $0.10/W premium over current technology. Due to uncertainty in future energy policy and barriers to market entry the technology to market analyses recommended partnering with an existing manufacturer. The industrial and transportation electric motor market was also identified as one standing to benefit from this material technology and key personnel within this market were identified. With the assistance of Dynapower the converter prototype was tested to 300 VDC (18 kVA) before the resonant capacitors failed. The prototype incorporated several subsystems including the passive and active components at the engineering scale and exposed at least one weak point in the prototype. Independent testing on the core materials predicts that the core would have met the operating specifications, but this component was not tested at nominal power. Based on this prediction and the demonstrated construction of the prototype core, we recommend that the core material is designated TRL 5. The CMU team is currently working with Eaton to identify opportunities further test cores in inductive components.