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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
DOE OSTI2022

Bifunctional Asymmetric Fabric with Tailored Thermal Conduction and Radiation for Personal Cooling and Warming

Personal thermal management is emerging as a promising strategy to provide thermal comfort for the human body while conserving energy. By improving control over the heat dissipating from the human body, personal thermal management can provide effective personal cooling and warming. Here, we propose a facile surface modification approach to tailor the thermal conduction and radiation properties based on commercially available fabrics, to realize better management of the whole heat transport pathway from the human body to the ambient. Additionally, a bifunctional asymmetric fabric (BAF) offering both a cooling and a warming effect is demonstrated. Due to the advantages of roughness asymmetry and surface modification, the BAF demonstrates an effective cooling effect through enhanced heat conduction and radiation in the cooling mode; in the warming mode, heat dissipation along both routes is reduced for personal warming. As a result, a 4.6 °C skin temperature difference is measured between the cooling and warming BAF modes, indicating that the thermal comfort zone of the human body can be enlarged with one piece of BAF clothing. We expect this work to present new insights for the design of personal thermal management textiles as well as a novel solution for the facile modification of available fabrics for both personal cooling and warming.

42 ENGINEERING↗
DOE OSTI2021

Effect of thermal environments on fast charging Li-ion batteries

Battery thermal management systems (BTMSs) are expected to keep the battery temperature at a moderate level (~30 °C) to minimize the thermally exacerbated degradation. However, during fast charging, a strong cooling system is required to restrict the temperature rise of Li-ion batteries (LiBs), which significantly increases the cost and weight of battery packs, and induces a large temperature variation inside the battery. Here, in this work, we find that all these drawbacks could be relieved by allowing LiBs to charge at higher temperatures. Since the fast charging of a LiB only takes a tiny fraction of its lifetime, the aging rate is limited even at a charging temperature of 60 °C. Three types of thermal environments are proposed: kept constant at 30 °C, preheated to 60 °C, and adiabatic fast charging. With an experimentally validated electrochemical-thermal (ECT) coupled model, we explore the interplay between thermal management and the fast-charging performance. It is found that a gradually increasing temperature profile is the best option to balance the lithium plating and thermal management of the battery. Combining adiabatic fast charging with a preheating step, we can achieve minimal cooling need, perfect temperature uniformity within a battery, and fast-charging capability simultaneously.

25 ENERGY STORAGE↗
DOE OSTI2026

Understanding Electric Vehicle Range and Charging Needs: Interactions Between Ambient Temperature, Commute Patterns, and State-of-Charge Usage

Electric vehicle (EV) performance can vary substantially under real-world operating conditions, particularly due to ambient temperature effects on energy consumption, battery behavior, and thermal management requirements. This study quantifies how weather conditions, daily driving patterns, and State-of-Charge (SOC) usage strategies jointly influence EV driving range, charging frequency, and overall energy efficiency. A detailed and experimentally validated Autonomie vehicle model is developed, integrating a powertrain, a mono-zonal cabin model, and a battery electro-thermal model. Three battery sizes (200-, 300-, and 400-mile homologated ranges) are assessed across five commute profiles (20–200 miles) and six ambient temperatures (−18 °C to 50 °C), including scenarios with and without preconditioning. Results show that extreme temperatures could significantly decrease the maximum achievable range by up to 55% in cold conditions (−18 °C) and 40% in hot conditions (50 °C), relative to moderate conditions. Larger battery packs retain a greater fraction of their nominal range under thermal stress, while smaller packs experience sharper relative penalties due to the higher contribution of thermal loads to total energy demand. The analysis further demonstrates that limiting operation to partial SOC windows (e.g., 80–20%), a common real-world practice, significantly reduces achievable range and increases charging frequency, particularly in cold weather. Thermal preconditioning while plugged in is shown to mitigate these effects for short trips, reducing energy consumption by up to 31% in hot conditions and 7% in cold conditions. The findings demonstrate how climate, SOC usage behavior, and thermal management jointly shape the practical driving capability of EVs, highlighting the importance of efficient thermal management and realistic user charging strategies for ensuring reliable EV operation across diverse climatic scenarios.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Analysis and Optimization of a Multi-Layer Integrated Organic Substrate for High Current GaN HEMT-Based Power Module

In this paper, analysis and optimization of a multi-layer organic substrate for high current GaN HEMT based power module are discussed. The organic multi-layer substrates can provide high electrical performance in terms of low parasitic inductance in the power loop by providing vertical layout, and shielding for reduction of common-mode noise, a common problem in fast switching power converters. Furthermore, high performance cooling solutions, such as micro-channel heat sinks, can be directly bonded to the substrate for optimum thermal management. The structure of the proposed architecture, thermal analysis and optimization of layer thickness, thermo-mechanical stress analysis of the GaN HEMT and development of a high-performance heat sink are discussed.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Reduced thermal resistance of Al-rich AlGaN HEMTs via top-side diamond integration

We report back-end-of-line growth of nanocrystalline diamond (NCD) on ultrawide bandgap (UWBG) high Al content aluminum gallium nitride (AlGaN) channel high electron mobility transistors for thermal management. A thin (∼15 nm) silicon nitride (SiN x ) interlayer was deposited to protect the device surface before performing a low temperature (500 °C) NCD growth process in an attempt to protect the gates on these fully fabricated devices. Notably, atomic force microscopy showed that the maximum lateral grain size exceeded 300 nm even though the film thickness was ∼250 nm. Comparing electrical (DC) performance before and after NCD growth, the gate leakage increased by ∼10 2 after NCD growth. Despite the lower NCD growth temperature, intermixing of the Ni and Au was observed in the Schottky gate metal stack; however, we believe there is another mechanism, possibly hydrogen-related, that is responsible for the measured increase in gate leakage. Regarding thermal management, the device-level thermal resistance (quantified using the average gate temperature rise measured by thermoreflectance imaging) was reduced by 29% through the incorporation of the top-side diamond film. Using time-domain thermoreflectance, the thermal conductivity of the ≈250 nm thick NCD film was measured to be 45 ± 25 W m −1 K −1 . This is expected to be at least 5× greater than the thermal conductivity of the thin disordered AlGaN alloy. There could also be a coupled electrothermal component contributing to the reduced temperature rise from electric field spreading and consequent heat spreading. This study demonstrates a promising first step toward device-level thermal management of high power UWBG Al-rich AlGaN devices.

Lundh, James Spencer [U.S. Naval Research Laborato↗
DOE OSTI2020

Heat Generation Concerns Associated with Extreme Fast Charging

Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. Incorrect thermal management designs for extreme fast charging conditions could result in cells reaching abuse temperatures and potentially sending the cells into thermal runaway. Furthermore, the cell and module design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and how to potentially measure the internal temperatures of a battery. Thermal management is not a limiting condition with regards to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2023

Microscale Imaging of Thermal Conductivity Suppression at Grain Boundaries

Abstract Grain‐boundary engineering is an effective strategy to tune the thermal conductivity of materials, leading to improved performance in thermoelectric, thermal‐barrier coatings, and thermal management applications. Despite the central importance to thermal transport, a clear understanding of how grain boundaries modulate the microscale heat flow is missing, owing to the scarcity of local investigations. Here, thermal imaging of individual grain boundaries is demonstrated in thermoelectric SnTe via spatially resolved frequency‐domain thermoreflectance. Measurements with microscale resolution reveal local suppressions in thermal conductivity at grain boundaries. Also, the grain‐boundary thermal resistance – extracted by employing a Gibbs excess approach – is found to be correlated with the grain‐boundary misorientation angle. Extracting thermal properties, including thermal boundary resistances, from microscale imaging can provide comprehensive understanding of how microstructure affects heat transport, crucially impacting the materials design of high‐performance thermal‐management and energy‐conversion devices.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Advanced Power Electronics and Electric Machines

The advanced power electronics and electric machines (APEEM) research group at the National Renewable Energy Laboratory (NREL) has developed world-class experimental and modeling capabilities for designing and evaluating efficient and reliable power electronics and electric machines thermal management systems. They also design, fabricate and characterize advanced power electronics packaging, and are developing state-of-health monitoring techniques. These researchers deliver safe, reliable, high performing, power-dense components that allow seamless integration between renewable energy sources, electric transportation, and the grid, helping to make widespread electric vehicle (EV) adoption and greenhouse gas emissions reduction more feasible. This document outlines the group's major capabilities in the areas of power electronics; module development and characterization; thermal modeling and management; thermomechanical reliability analysis of devices, modules, inverters/converters, and electric machines; physics-of-failure-based reliability analysis; and microelectronics. It also overviews the group's state-of-the-art equipment for fluid-based thermal management; thermal measurement & characterization; thermomechanical reliability analysis; micro- and power electronics measurement & characterization; and prototype fabrication, as well as the group's world-class modeling and simulation capabilities.

advanced gate drivers↗
DOE OSTI2025

Local Thermal Conductivity Patterning in Rotating Lattice Crystals of Anisotropic Sb 2 S 3

The ability to control material heat transport properties over space and time can drive advanced functionalities in thermal management for electronics and system-on-chip, and enable thermal circuits. Despite the technological relevance, there are limited demonstrations of local thermal property control. Rotating lattice single (RLS) crystals—formed via laser-induced crystallization of an amorphous substrate—offer a novel avenue for local crystal engineering, unlocking opportunities for microscale property patterning. Here, thermal conductivity (𝜅) imaging is applied to RLS crystals of Sb2S3 to resolve microscale 𝜅 variations across patterned regions. Amorphous areas exhibit 𝜅 as low as 0.6 Wm −1 K −1 , while crystalline regions display periodic 𝜅 variations from 0.7 to over 2.5 Wm −1 K −1 . These variations correspond to changes in crystal orientation, revealing marked 𝜅 anisotropy. The crystal out-of-plane direction (c axis)—featuring van der Waals bonds—shows amorphous-like transport, whereas in-plane directions (a, b axes) exhibit 3.5x and 1.7x larger 𝜅, respectively. First-principles calculations, in excellent agreement with experiments, suggest that the in-plane anisotropy originates from expressed Sb lone pairs, which impart a corrugation along the b axis affecting bond stiffness and 𝜅. These findings demonstrate microscale control of thermal properties via laser-processed metastructures, with significant implications for next-generation thermal management.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermal Transport and Mechanical Stress Mapping of a Compression Bonded GaN/Diamond Interface for Vertical Power Devices

Bonding diamond to the back side of gallium nitride (GaN) electronics has been shown to improve thermal management in lateral devices; however, engineering challenges remain with the bonding process and characterizing the bond quality for vertical device architectures. Here, in this study, integration of these two materials is achieved by room-temperature compression bonding centimeter-scale GaN and a diamond die via an intermetallic bonding layer of Ti/Au. Recent attempts at GaN/diamond bonding have utilized a modified surface activation bonding (SAB) method, which requires Ar fast atom bombardment immediately followed by bonding within the same tool under ultrahigh vacuum (UHV) conditions. The method presented here does not require a dedicated SAB tool yet still achieves bonding via a room-temperature metal–metal compression process. Imaging of the buried interface and the total bonding area is achieved via transmission electron microscopy (TEM) and confocal acoustic scanning microscopy (C-SAM), respectively. The thermal transport quality of the bond is extracted from spatially resolved frequency-domain thermoreflectance (FDTR) with the bonded areas boasting a thermal boundary conductance of >100 MW/m 2 ·K. Additionally, Raman maps of GaN near the GaN–diamond interface reveal a low level of compressive stress, <80 MPa, in well-bonded regions. FDTR and Raman were coutilized to map these buried interfaces and revealed some poor thermally bonded areas bordered by high-stress regions, highlighting the importance of spatial sampling for a complete picture of bond quality. Overall, this work demonstrates a novel method for thermal management in vertical GaN devices that maintains low intrinsic stresses while boasting high thermal boundary conductances.

Raman↗
DOE OSTI2020

Graphite-Embedded High-Performance Insulated Metal Substrate for Wide-Bandgap Power Modules

Emerging wide-bandgap (WBG) semiconductor devices such as silicon carbide (SiC) metal–oxide semiconductor field-effect transistors (MOSFETs) and gallium nitride high-electron-mobility transistors can handle high power in reduced semiconductor areas better than conventional Si-based devices owing to superior material properties. With increased power loss density in a WBG-based converter and reduced die size in power modules, thermal management of power devices must be optimized for high performance. Here, we present a graphite-embedded insulated metal substrate (thermally-annealed-pyrolytic-graphite-embedded insulated metal substrate—IMSwTPG) designed for WBG power modules. Theoretical thermal performance analysis of graphite-embedded metal cores is presented, with design details for IMSwTPG with embedded graphite to replace a direct-bonded copper (DBC) substrate. The proposed IMSwTPG is compared with an aluminum nitride-based DBC substrate using finite-element thermal analysis for steady-state and transient thermal performance. The solutions’ thermal performances are compared under different coolant temperature and thermal loading conditions, and the proposed substrate's electrical performance is validated with static and dynamic characterization. Using graphite-embedded substrates, junction-to-case thermal resistance of SiC MOSFETs can be reduced up to 17%, and device current density can be increased by 10%, regardless of the thermal management strategy used to cool the substrate. Reduced transient thermal impedance of up to 40% of dies owing to increased heat capacity is validated in transient thermal simulations and experiments. The half-bridge power module's electrical performance is evaluated for on -state resistance, switching performance, and switching loss at three junction temperature conditions. The proposed substrate solution has minimal impact on conduction and switching performance of SiC MOSFETs.

42 ENGINEERING↗
DOE OSTI2023

Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE)

Raytheon Technologies Research Center (RTRC) is the central research and development (R&D) organization for RTX, and has extensive expertise in the design, modeling and analysis of high-performance electrical machines and thermal management for all its business units. The proposing team consists of researchers from RTRC and John Deere (JD), will be referred as “Team”. Each organization a has long track record of successful R&D of materials, manufacturing, components, and systems for energy efficiency applications. Motor power density and efficiency are limited by fundamental physical trade-offs between electromagnetics, thermal management, and structural design considerations. The team is proposing to utilize novel technologies and multi-physics design methods to develop a Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE), demonstrating an 8X improvement in power density.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Actively controlled coolant tank to increase thermal storage capacity of hybrid electric vehicles

An engine and cabin thermal management system for use with a vehicle having an engine, a cabin heating system configured to thermally heat a cabin of the vehicle, a coolant system operably coupled to the engine and to the cabin heating system to thermally manage a temperature of the engine and a temperature of the cabin. The coolant system having one or more coolant thermal storage units fluidly coupled with a radiator and heater core of the coolant system forming a coolant loop. The system further having a control system configured to monitor and maintain at least a predetermined coolant temperature at the cabin heating system even during a coolant temperature decrease at the engine stops.

Amini, Mohammad Reza↗
DOE OSTI2021

DPC Disposal Concepts of Operations. Final Report

The U.S. Department of Energy supports an R&D program for evaluating approaches to direct disposal of commercial spent fuel in dual-purpose canisters (DPCs). The major thrusts include alternative measures for treating the possibility of internal criticality events in DPC-based waste packages after thousands of years in a repository. These measures include: 1) injectable fillers, 2) analysis of the consequences of criticality events in a repository should they occur, and 3) options for modifying fuel assemblies or baskets in DPCs at the time they are loaded. This report presents a snapshot of progress in each of these areas drawing on deliverable reports generated during FY18 through FY20. Another aspect of the R&D program is to develop concepts of operations for repositories that would permanently dispose of DPC-based waste packages, considering different generic host media (not site-specific). The idea is to examine whether the disposal of large, heavy, heat-generating waste packages is technically feasible, and to identify the engineering challenges that would arise during implementation of the different disposal concepts. Descriptions of repository features are presented for repositories in salt media, argillite (clay/shale) media, crystalline (e.g., granitic) media, and unsaturated media (considering either alluvium or hard rock). Thermal management criteria for each concept are presented in terms of the maximum waste package thermal power at emplacement, when the repository could be opened, and the duration of repository emplacement operations. The overall message of this report is that direct disposal of commercial spent fuel is technically feasible in different types of geologic host media, but that thermal management and postclosure criticality impose different constraints on each concept. Engineering challenges are recognized and discussed. Treatment of postclosure criticality is identified as an important technical question that receives the majority of attention in the R&D program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Thermal regulation of batteries

A battery thermal management system for an air vehicle includes a first heat exchange circuit, a battery in thermal communication with the first heat exchange circuit, and a heat exchanger positioned on the first heat exchange circuit. The heat exchanger is operatively connected to a second heat exchange circuit. The system includes a controller operatively connected to the second heat exchange circuit. The controller is configured to variably select whether heat will be rejected to the second heat exchange circuit. A method for controlling a thermal management system for an air vehicle includes determining an expected fluid temperature of fluid in a fluid heat exchange circuit. The method includes commanding a flow restrictor at least partially closed or commanding the flow restrictor at least partially open.

Macdonald, Malcolm↗
DOE OSTI2021

Development of an Advanced Hydrogen Energy Storage System using Aerogel in a Cryogenic Flux Capacitor (CFC)

The Cryogenic Flux Capacitor (CFC) is a cold, dense fluid storage core with integrated design features that afford the designer flexibility and provide new possibilities for the storage and discharge of energy. The stored energy, in this case, is represented by hydrogen physically bonded within the nanoscale pores within the aerogel composite blanket material, and the process of bonding or debonding is governed by principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m2/g) allows for storage densities close to, or in some cases exceeding, that of normal boiling point liquids. Its performance easily exceeds what can be achieved via ambient temperature, high-pressure gas storage for an equivalent volume. CFC storage is predicted to be easily scalable, is constructed from readily available commercial materials, lends itself to a range of pressure applications, and is geometry insensitive. They can also be used in modular designs, affording even more flexibility for potential deployment. In addition to the aerogel adsorbent within the blanket material, a CFC includes thermally-conductive membrane layered with the aerogel, which acts as a large-area, quick-response thermal management system. The system conducts heat throughout the volume to discharge the unit quickly. This same thermal management system can also be connected to a refrigeration system, or cold fluid such as liquid nitrogen (LN2), to facilitate the charging up of the CFC. The charging and discharging can be performed as fast or as slow as desired by controlling the cooling or heating supplied to the CFC.

08 HYDROGEN↗
DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗