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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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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Current limiting remote power control module

The power source for the Space Station Freedom will be fully utilized nearly all of the time. As such, any loads on the system will need to operate within expected limits. Should any load draw an inordinate amount of power, the bus voltage for the system may sag and disrupt the operation of other loads. To protect the bus and loads some type of power interface between the bus and each load must be provided. This interface is most crucial when load faults occur. A possible system configuration is presented. The proposed interface is the Current Limiting Remote Power Controller (CL-RPC). Such an interface should provide the following power functions: limit overloading and resulting undervoltage; prevent catastrophic failure and still provide for redundancy management within the load; minimize cable heating; and provide accurate current measurement. A functional block diagram of the power processing stage of a CL-RPC is included. There are four functions that drive the circuit design: rate control of current; current sensing; the variable conductance switch (VCS) technology; and the algorithm used for current limiting. Each function is discussed separately.

Hopkins, Douglas C.↗
NASA NTRS1993

Heat pipe cooled heat rejection subsystem modelling for nuclear electric propulsion

NASA LeRC is currently developing a FORTRAN based computer model of a complete nuclear electric propulsion (NEP) vehicle that can be used for piloted and cargo missions to the Moon or Mars. Proposed designs feature either a Brayton or a K-Rankine power conversion cycle to drive a turbine coupled with rotary alternators. Both ion and magnetoplasmodynamic (MPD) thrusters will be considered in the model. In support of the NEP model, Rocketdyne is developing power conversion, heat rejection, and power management and distribution (PMAD) subroutines. The subroutines will be incorporated into the NEP vehicle model which will be written by NASA LeRC. The purpose is to document the heat pipe cooled heat rejection subsystem model and its supporting subroutines. The heat pipe cooled heat rejection subsystem model is designed to provide estimate of the mass and performance of the equipment used to reject heat from Brayton and Rankine cycle power conversion systems. The subroutine models the ductwork and heat pipe cooled manifold for a gas cooled Brayton; the heat sink heat exchanger, liquid loop piping, expansion compensator, pump and manifold for a liquid loop cooled Brayton; and a shear flow condenser for a K-Rankine system. In each case, the final heat rejection is made by way of a heat pipe radiator. The radiator is sized to reject the amount of heat necessary.

Moriarty, Michael P.↗
NASA NTRS2014

Water Transport and the Evolution of CM Parent Bodies

Extraterrestrial water-bearing minerals are of great importance both for understanding the formation and evolution of the solar system and for supporting future human activities in space. Asteroids are the primary source of meteorites, many of which show evidence of an early heating episode and varying degrees of aqueous alteration. The origin and characterization of hydrated minerals (minerals containing H2O or OH) among both the main-belt and near-earth asteroids is important for understanding a wide range of solar system formation and evolutionary processes, as well as for planning for human exploration. Current hypotheses postulate asteroids began as mixtures of water ice and anhydrous silicates. A heating event early in solar system history was then responsible for melting the ice and driving aqueous alteration. The link between asteroids and meteorites is forged by reflectance spectra, which show 3-μm bands indicative of bound OH or H2O on the C-class asteroids, which are believed to be the parent bodies of the carbonaceous chondrites in our collections. The conditions at which aqueous alteration occurred in the parent bodies of carbonaceous chondrites are thought to be well-constrained: at 0-25 C for less than 15 Myr after asteroid formation. In previous models, many scenarios exhibit peak temperatures of the rock and co-existing liquid water in more than 75 percent of the asteroid's volume rising to 150 C and higher, due to the exothermic hydration reactions triggering a thermal runaway effect. However, even in a high porosity, water-saturated asteroid very limited liquid water flow is predicted (distances of 100's nm at most). This contradiction has yet to be resolved. Still, it may be possible for water to become liquid even in the near-surface environment, for a long enough time to drive aqueous alteration before vaporizing or freezing then subliming. Thus, we are using physics- and chemistry-based models that include thermal and fluid transport as well as the effects of relevant chemical reactions, to investigate whether formation of hydrated minerals can occur in the surface and near-surface environments of carbonaceous type asteroids. These models will elucidate how the conditions within the parent body that cause internal aqueous alteration play themselves out at the asteroid's surface. We are using our models to determine whether the heat budget of 20-100-km bodies is sufficient to bring liquid water to the near-surface and cause mineral alteration, or whether additional heat input at the surface (i.e, by impacts) is needed to provide a transient liquid water source for mineral hydration without large- scale liquid water transport.

Coker, R.↗
DOE OSTI2024

Coupled model for liquid lithium plasma facing components

Numerical analysis provides the design choice and operating window of liquid metal Plasma Facing Components (PFC) concepts. Coupled analysis of boundary plasma together with the surrounding boundary structures is required. Here, to achieve this goal, PPPL is developing a comprehensive multi-physics model for modeling of PFCs in fusion devices. The model includes the fluid-kinetic code SOLPS-ITER and the flow and heat transfer code CFX from ANSYS. SOLPS-ITER was augmented with a liquid metal boundary condition algorithm, allowing direct two-way coupling of the plasma analysis with the two-dimensional analytical slab flow model which includes heat convection in the liquid metal PFC. The target heat flux resulting from this coupled analysis is used as a boundary condition for detailed 3D Computational Fluid Dynamics (CFD) Magneto Hydro Dynamics (MHD) and heat transfer analysis. A new formulation of MHD equations is introduced in the numerical procedure ensuring current conservation of the discretized equations. Results of the 3D analysis are used for final validation of the coupled model. A PFC design where a porous wall is used to stabilize the liquid metal surface, while MHD drive is used to push the liquid metal flow inside the PFC, will be investigated in the regimes where vapor shielding is created for enhanced volumetric plasma heat dissipation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2002

Spin-Up Instability of a Levitated Molten Drop in MHD-Flow Transition to Turbulence

When an alternating magnetic field interacts with induced eddy currents in a conducting body, there will be a repulsive force between the body and the driving coil system generating the field. This repulsive force is the basis of electromagnetic levitation, which allows containerless processing of different materials. The eddy currents in the conducting body also generate Joule heating. Axial rotation of electromagnetically levitated objects is a common observation in levitation systems and often an undesirable side effect of such experiments on 1-g and -g. There have been recent efforts to use magnetic damping and suppress this tendency of body rotation. The first report of rotation in EML drops was attributed to a slight asymmetry of the shape and location of the levitation coils could change the axis and speed of rotation. Other theories of sample rotation include a frequency difference in the traveling electromagnetic waves and a phase difference in two different applied fields of the same frequency. All of these different mechanisms share the following characteristics: the torque is small, constant for constant field strength, and very weakly dependent on the sample's temperature and phase (solid or liquid). During experiments on the MSL-1 (First Microgravity Science Laboratory) mission of the Space Shuttle (STS-83 and STS-94, April and July 1997), a droplet of palladium-silicon alloy was electromagnetically levitated for viscosity measurements. For the non-deforming droplet, the resultant MHD flow inside the drop is inferred from motion of impurities on the surface. These observations indicate formation of a pair of co-rotating toroidal flow structures inside the spheroidal levitated drop that undergo secondary flow instabilities. As rise in the fluid temperature rises, the viscosity falls and the internal flow accelerates and becomes oscillatory; and beyond a point in the experiments, the surface impurities exhibit non-coherent chaotic motion signifying emergence of turbulence inside the drop. In this work, a background of these set of observations will be given followed by a presentation of our results on the digital particle tracking analysis that has been performed on a number of available videos. The analysis indicates that the levitated drop attains a constant rotational speed during the melting phase and formation of the co-rotating axi-symmetric laminar toroidal structures. However, the rate of axial rotation increases dramatically during the deformation of the toroidal structures anti their breakup into chaotic entities. This new data suggests an interaction between the flow inside the levitated molten drop and the driving coils in the experiments. Possible mechanisms for this interaction will be reviewed. The data will also be used to make an assessment of existing theories on droplet rotation.

Abedian, B.↗
NASA NTRS2009

Physical Processes for Driving Ionospheric Outflows in Global Simulations

We review and assess the importance of processes thought to drive ionospheric outflows, linking them as appropriate to the solar wind and interplanetary magnetic field, and to the spatial and temporal distribution of their magnetospheric internal responses. These begin with the diffuse effects of photoionization and thermal equilibrium of the ionospheric topside, enhancing Jeans' escape, with ambipolar diffusion and acceleration. Auroral outflows begin with dayside reconnexion and resultant field-aligned currents and driven convection. These produce plasmaspheric plumes, collisional heating and wave-particle interactions, centrifugal acceleration, and auroral acceleration by parallel electric fields, including enhanced ambipolar fields from electron heating by precipitating particles. Observations and simulations show that solar wind energy dissipation into the atmosphere is concentrated by the geomagnetic field into auroral regions with an amplification factor of 10-100, enhancing heavy species plasma and gas escape from gravity, and providing more current carrying capacity. Internal plasmas thus enable electromagnetic driving via coupling to the plasma, neutral gas and by extension, the entire body " We assess the Importance of each of these processes in terms of local escape flux production as well as global outflow, and suggest methods for their implementation within multispecies global simulation codes. We complete 'he survey with an assessment of outstanding obstacles to this objective.

Moore, Thomas Earle↗
NASA NTRS2015

Testing of an Arcjet Thruster with Capability of Direct-Drive Operation

Electric thrusters typically require a power processing unit (PPU) to convert the spacecraft provided power to the voltage-current that a thruster needs for operation. Testing has been initiated to study whether an arcjet thruster can be operated directly with the power produced by solar arrays without any additional conversion. Elimination of the PPU significantly reduces system-level complexity of the propulsion system, and lowers developmental cost and risk. The work aims to identify and address technical questions related to power conditioning and noise suppression in the system and heating of the thruster in long-duration operation. The apparatus under investigation has a target power level from 400-1,000 W. However, the proposed direct-drive arcjet is potentially a highly scalable concept, applicable to solar-electric spacecraft with up to 100's of kW and beyond. A direct-drive electric propulsion system would be comprised of a thruster that operates with the power supplied directly from the power source (typically solar arrays) with no further power conditioning needed between those two components. Arcjet thrusters are electric propulsion devices, with the power supplied as a high current at low voltage; of all the different types of electric thruster, they are best suited for direct drive from solar arrays. One advantage of an arcjet over Hall or gridded ion thrusters is that for comparable power the arcjet is a much smaller device and can provide more thrust and orders of magnitude higher thrust density (approximately 1-10 N/sq m), albeit at lower I(sub sp) (approximately 800-1000 s). In addition, arcjets are capable of operating on a wide range of propellant options, having been demonstrated on H2, ammonia, N2, Ar, Kr, Xe, while present SOA Hall and ion thrusters are primarily limited to Xe propellant. Direct-drive is often discussed in terms of Hall thrusters, but they require 250-300 V for operation, which is difficult even with high-voltage solar arrays. The arcjet requires under 100 V, which is more in-line with what is easily possible with a solar array. Direct-drive of an electric propulsion system confers the advantage of reducing or eliminating the power processing unit (PPU) that is typically needed to convert the spacecraft-provided power to the voltage and current needed for thruster operation. Since the PPU is typically the most expensive piece of an electric thruster system, from both a fabrication and qualification standpoint, its elimination offers the potential for major reductions in system cost and risk. The design of the arcjet built for this effort was based on previous low power (1 kW class) arcjets. It has a precision machined 99.95% pure tungsten anode which also serves as the nozzle. The anode constrictor region is 1 mm (0.040-in) diameter and 1 mm (0.040-in) long. The cathode is a tungsten welding electrode doped with LaO2; its tip was precision ground to a 30◦ angle ending in a blunt end. The two electrodes are separated by a boron-nitride insulator which also serves as the propellant injection manifold; it ends in six small holes which introduce the propellant gas in the diverging section of the nozzle, directly adjacent to the cathode. The electrodes and insulator are housed in a stainless-steel outer-body, with a Macor insulator at the mid-plane to provide thermal isolation between the front and back halves of the device. The gas seals were made using Grafoil gaskets. Figure 1A shows the assembled thruster in the vacuum chamber; figure 1B shows the thruster in operation on argon at a flow rate of 676 sccm (20 mg/s). Initial testing was conducted in a 3.5-ft diameter vacuum chamber; the ultimate pressure reached during quasi-steady operation of the thruster was about 330 millitorr. The thruster was powered with a high-current, 0-100A, 15 kW power supply. The discharge was initiated with a high-voltage (approximately 10 kV) spark initiator that was isolated from the supply by a stack of diodes. The testing indicated that an operating point exists within the I-V characteristics that is compatible with direct-drive solar-electric operation; for a flow rate of 20 mg/s (argon) the arc could be sustained at a voltage of about 20 V and a current of 25 A (500W).

Martin, Adam K.↗
DOE OSTI2022

Length and Seed Current Scaling of a Mark X HG driven, 8 inch PBX9501 RancheroS FCG system: II

This report is intended to examine the ultimate operating limits of the combined Pt. 88 capacitor bank (CB) + MarkX Helical Generator (HG) driving a RancheroS Flux Compression Generator (FCG) with various physics experiment load inductances. As such, many degradation mechanisms are neglected in this study. In actual use, degradation of the HG output current delivered to the FCG will probably occur. Internal changes in the HG can occur due to both Ohmic heating in the generator leading to a time varying series resistance [R(t)] such as that seen in the first trial (Shot 0) of the MarkX, as well as any misbehavior, such HG internal turn to turn shorts such as seem to have occurred in subsequent MarkX tests. Both reduce the output current from the HG that is used to seed the FCG. The results discussed here are intended to probe the limits of the RancheroS driving various loads, in an ideal situation in which none of the HG or system degradation mechanisms prior to the FCG armature first motion (FM) reduce the seed current. The HG is modeled simply as a time varying inductance [L(t), as measured in Shot 0], with a constant internal resistance [R(t) = 0.2mOhm]. The RancheroS itself is fully modeled, including all FCG and load degradation mechanisms, thus probing the ultimate capabilities of the full system, independent of problems upstream of the FCG.

47 OTHER INSTRUMENTATION↗
NASA NTRS1989

Small Displacement, Long Life On-Orbit Compressor Design and Fabrication

The focus is the generation of technology and fabrication of prototype hardware applicable to seven Space Station compressor system applications. The compressors are of the single acting reciprocating piston type and, in general, may be termed miniature in size compared with normal commercially available equipment. The initial technology development is focused on improved valve designs, and the control of pulsations and heating effects in order to increase compressor efficiency and reduce cycle temperatures, thus permitting significantly increased stage pressure ratios. The initial test compressor was successfully operated at pressure ratios of up to 50:1, and this significant extension of allowable pressure ratio will result in a reduction of the number of required stages and, hence, total hardware thereby reducing system weight and volume. These experiments have also identified the need to employ low shaft speeds, on the order of 250 to 500 rpm, to enhance heat transfer and increase life. The prototype compressor currently being designed, is to be driven by a low-speed brushless dc motor sealed in a case common to the compressor drive mechanism case. The compressor and motor case will communicate with stage suction pressure so that any minor gas leakage past the piston rings will be returned to the suction. Emphasis in this prototype design is being placed on simplicity, durability, commonality of components, and high efficiency.

Gerlach, C. R.↗
NASA NTRSDate not supplied

Atmospheric Escape from Magnetized Rocky Exoplanets

Recent Kepler and TESS observations discovered many rocky exoplanets in habitable zones around active main-sequence stars. The upper atmospheres of exoplanets are subject to two important energy sources derived from their host stars. First, the stellar photon flux in the X-ray and XUV bands ionizes and heats the upper atmosphere, driving atmospheric heating, affecting the conductance, and enhancing atmospheric escape. Second, the stellar wind’s interaction with the exoplanet’s intrinsic magnetic field transfers energy to the atmosphere through field aligned currents and Poynting flux. That energy is dissipated in the high latitude cusp and auroral regions through Joule heating which can inflate the atmosphere and also enhance the atmospheric escape rate. This presentation will discuss recent advances in modeling these energy inputs and their consequences for exoplanetary habitability. Also, I will discuss the development of a new model, the (exo) PLANETary Ionosphere-Thermosphere Tool for Research (PLANET-ITTR) and some early results from it.

William Danchi↗
DOE OSTI2021

Multiphysics simulations of a steady-state lower hybrid current drive antenna for the FSNF

The Fusion Nuclear Science Facility (FNSF) is a proposed tokamak reactor with the mission to investigate operation of a fusion reactor in a nuclear environment. The high neutron fluence component of the FNSF mission requires steady-state operation for extremely long pulses (t_{pulse} ∼ months) at full power. Plasma sustainment and current drive will be critical components of a successful FNSF. COMSOL Multiphysics software is used for combined radiofrequency (RF) and thermal simulations of the lower hybrid current drive (LHCD) antenna system. These simu- lations consider the resistive RF losses in the antenna including realistic surface roughness and a range of potential materials. The thermal analysis adds volumetric nuclear heating, plasma heat flux on leading edges, and electromagnetic radiation from the plasma to the RF heating calculated by COMSOL. Additional neutronics calculations have been performed to determine the impact of these antenna designs on activated waste disposal for the materials considered. The simulations show that it is technically feasible to implement a fully-active multi-junction (FAM) rather than a passive-active multi-junction (PAM) style of antenna if the septum between adjacent waveguides is sufficiently wide and the thermal conductivity of the structural material is sufficiently high. The FAM has the benefit of higher achievable power density with respect to the PAM, which results in a more compact antenna with potentially lower impact on neutron shielding and tritium breeding. These considerations point to tungsten rather than steel as the preferred structural material in constructing the antenna.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2014

Magnetic Structure of Sites of Braiding in Hi-C Active Region

High‐resolution Coronal Imager (Hi‐C) observations of an active region (AR) corona, at a spatial resolution of 0.2 arcsec, have offered the first direct evidence of field lines braiding, which could deliver sufficient energy to heat the AR corona by current dissipation via magnetic reconnection, a proposal given by Parker three decades ago. The energy required to heat the corona must be transported from the photosphere along the field lines. The mechanism that drives the energy transport to the corona is not yet fully understood. To investigate simultaneous magnetic and intensity structure in and around the AR in detail, we use SDO/HMI+AIA data of + / ‐ 2 hours around the 5 minute Hi‐C flight. In the case of the QS, work done by convection/granulation on the inter‐granular feet of the coronal field lines probably translates into the heat observed in the corona. In the case of the AR, as here, there could be flux emergence, cancellation/submergence, or shear flows generating large stress and tension in coronal field loops which is released as heat in the corona. However, to the best of our knowledge, there is no observational evidence available to these processes. We investigate the changes taking place in the photospheric feet of the magnetic field involved with brightenings in the Hi‐C AR corona. Using HMI 45s magnetograms of four hours we find that, out of the two Hi‐C sub‐regions where the braiding of field lines were recently detected, flux emergence takes place in one region and flux cancellation in the other. The field in these sub‐regions are highly sheared and have apparent high speed plasma flows at their feet. Therefore, shearing flows plausibly power much of the coronal and transition region heating in these areas of the AR. In addition, the presence of large flux emergence/cancellation strongly suggests that the work done by these processes on the pre‐existing field also drives much of the observed heating.

Tiwari, S. K.↗
NASA NTRS2013

Investigation of Abnormal Grain Growth in a Friction Stir Welded and Spin-Formed Al-Li Alloy 2195 Crew Module

In order to improve manufacturing efficiency and reduce structural mass and costs in the production of launch vehicle structures, NASA is pursuing a wide-range of innovative, near-net shape manufacturing technologies. A technology that combines friction stir welding (FSW) and spin-forming has been applied to manufacture a single-piece crew module using Aluminum-Lithium (AL-Li) Alloy 2195. Plate size limitations for Al-Li alloy 2195 require that two plates be FSW together to produce a spin-forming blank of sufficient size to form the crew module. Subsequent forming of the FSW results in abnormal grain growth (AGG) within the weld region upon solution heat treatment (SHT), which detrimentally impacts strength, ductility, and fracture toughness. The current study seeks to identify microstructural factors that contribute to the development of AGG. Electron backscatter diffraction (EBSD) was used to correlate driving forces for AGG, such as stored energy, texture, and grain size distributions, with the propensity for AGG. Additionally, developmental annealing treatments prior to SHT are examined to reduce or eliminate the occurrence of AGG by promoting continuous, or uniform, grain growth

Tayon, Wesley A.↗
NASA NTRS1998

A Transport Model for Non-Local Heating of Electrons in ICP Reactors

A new model has been developed for non-local heating of electrons in ICP reactors, based on a hydrodynamic approach. The model has been derived using the electron momentum conservation in azimuthal direction with electromagnetic and frictional forces respectively as driving force and damper of harmonic oscillatory motion of electrons. The resulting transport equations include the convection of azimuthal electron momentum in radial and axial directions, thereby accounting for the non-local effects. The azimuthal velocity of electrons and the resulting electrical current are coupled to the Maxwell's relations, thus forming a self-consistent model for non-local heating. This model is being implemented along with a set of Navier-Stokes equations for plasma dynamics and gas flow to simulate low-pressure (few mTorr's) ICP discharges. Characteristics of nitrogen plasma in a TCP 300mm etch reactor is being studied. The results will be compared against the available Langmuir probe measurements.

Chang, C. H.↗
DOE OSTI2021

Diii-D Research Advancing The Physics Basis For Optimizing The Tokamak Approach To Fusion Energy

DIII-D physics research addresses critical challenges for operation of ITER and the next generation of fusion energy devices. This is done through a focus on innovations to provide solutions for high performance long pulse operation, coupled with fundamental plasma physics understanding and model validation, to drive scenario development by integrating high performance core and boundary plasmas. Substantial increases in off-axis current drive efficiency from an innovative top launch system for EC power, and in pressure broadening for Alfven eigenmode control from a co-/counter-Ip steerable off-axis neutral beam, all improve the prospects for optimization of future long pulse/steady state high performance tokamak operation. Fundamental studies into the modes that drive the evolution of the pedestal pressure profile and electron vs. ion heat flux validate predictive models of pedestal recovery after ELMs. Understanding the physics mechanisms of ELM control and density pumpout by 3D magnetic perturbation fields leads to confident predictions for ITER and future devices. Validated modeling of high-Z shattered pellet injection for disruption mitigation, runaway electron dissipation, and techniques for disruption prediction and avoidance including machine learning, give confidence in handling disruptivity for future devices. With this physics understanding and suite of actuators, a high poloidal beta optimized-core scenario with an internal transport barrier that projects nearly to Q=10 in ITER at 9 MA was coupled to a detached divertor, and a near Super H-mode optimized-pedestal scenario with co-Ip beam injection, was coupled to a radiative divertor. The Hybrid core scenario was achieved directly, without the need for internal flux pumping, using off-axis current drive actuators, and a controller to avoid mode locking and disruptions in the ITER baseline scenario, based on plasma response to probing 3D fields, was demonstrated. Finally innovative tokamak operation using a negative triangularity shape showed many attractive features for future pilot plant operation.

Fenstermacher, M.↗
NASA NTRS1986

Liquid belt radiator design study

The Liquid Belt Radiator (LBR) is an advanced concept developed to meet the needs of anticipated future space missions. A previous study documented the advantages of this concept as a lightweight, easily deployable alternative to present day space heat rejection systems. The technical efforts associated with this study concentrate on refining the concept of the LBR as well as examining the issues of belt dynamics and potential application of the LBR to intermediate and high temperature heat rejection applications. A low temperature point design developed in previous work is updated assuming the use of diffusion pump oil, Santovac-6, as the heat transfer media. Additional analytical and design effort is directed toward determining the impact of interface heat exchanger, fluid bath sealing, and belt drive mechanism designs on system performance and mass. The updated design supports the earlier result by indicating a significant reduction in system specific system mass as compared to heat pipe or pumped fluid radiator concepts currently under consideration (1.3 kg/sq m versus 5 kg/sq m).

Teagan, W. P.↗
DOE OSTI2022

Thermoelectric coatings for waste heat recovery and photo-thermal power

An energy harvesting system for collecting energy from sources of thermal energy that exist in the environment and convert the energy to electricity. The system has N-P junctions mounted on the outer surface of a conduit, pipe or flue. A hot medium flows through the conduit, pipe or flue. The p-n junctions operate as thermoelectric power generators. Heat absorbed at the p-n junctions increases the kinetic energy of charge carriers causing migration of the charge carriers. This thermally-driven migration of charge carriers is used to drive an electrical current in an external circuit.

Farmer, Joseph C.↗
DOE OSTI2021

Electric-Drive Vehicle Power Electronics Thermal Management: Current Status, Challenges, and Future Directions

Effective thermal management of traction-drive power electronics is critical to the advancement of electric-drive vehicles and is necessary for increasing power density and improving reliability. Replacing traditional silicon devices with more efficient, higher temperature, higher voltage, and higher frequency wide-bandgap (WBG) devices will enable increased power density but will result in higher device heat fluxes. Compact packaging of high-temperature WBG devices near low-temperature-rated components creates thermal management challenges that need to be addressed for future power-dense systems. This paper summarizes the thermal performance of on-road automotive power electronics thermal management systems and provides thermal performance and pumping-power metrics for select vehicles. Thermal analyses reveal that the package/conduction resistance dominates the total thermal resistance (for existing automotive systems). We model advanced packaging concepts and compare the results with existing packaging designs to quantify their thermal performance enhancements. Double-side-cooled configurations that do not use thermal interface materials are package concepts predicted to provide a low junction-to-fluid thermal resistance (compared to current packages). Dielectric-fluid-cooled concepts enable a redesign of the package to reduce the package resistance, can be implemented in single- and two-phase cooling approaches, and allow for cooling of passive components (e.g., capacitors) and bus bars.

33 ADVANCED PROPULSION SYSTEMS↗