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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1986

Removing Heat From Toroidal Inductors

Bracket for mounting toroidal inductors adapted for removing heat and providing support. Copper windings wound around bracket instead of directly on core. Heat-dissipating mounting bracket encircles hollow cylindrical magnetic core. Core wrapped with toroidal winding and encapsulated in usual way. Bracket provides direct path for heat to leave both core and windings.

Mclyman, C. W. T.↗
DOE OSTI2026

Divertor detachment characterization in negative triangularity discharges in DIII-D via 2D edge-plasma transport modeling

Edge fluid modeling of the first divertor-plasma detachment experiments in negative triangularity (NT) discharges in the DIII-D tokamak is presented using the 2D multifluid edge transport code UEDGE, including cross-field particle drifts. Experiments were performed where the lower single-null magnetic equilibrium had a strong NT (δ≈−0.5), that is, where the magnetic X-point is at a larger major radius than the core magnetic axis. Divertor-plasma detachment was induced by increasing the core plasma density in DIII-D via intrinsic gas puffing. Here density scans are performed with UEDGE to reach a detached plasma and to quantitatively recover the experimental rollover of the ion saturation current on the outer divertor target plate. The simulations cover experiments with both signs of the toroidal magnetic field, B T , where the ion magnetic Grad-B drifts are directed into (forward B T ) and out of (reverse B T ) the divertor region. Consistent with experiments with neutral beam power injection, the NT simulations reproduce: 40% higher density is needed to reach detachment onset with forward B T compared with reverse B T , and the absence of deep detachment is found with reverse B T . Similarly, comparison between Ohmic discharges in NT and positive triangularity (PT) shaping confirms that a substantially higher density is needed to achieve detachment in NT than in PT, with NT requiring an line-average density of at least the Greenwald density or higher. Simulation results suggest that higher densities are needed to reach detachment in negative compared to PT because these discharges have a shorter midplane-to-target distance along the total magnetic field B, a shorter outer divertor poloidal leg length (0.06 m vs 0.2 m), and reduced radial transport [near-scrape-off layer (SOL) D ⊥ /χ ⊥ =0.3/0.5 vs D ⊥ /χ ⊥ =1.0/1.0, all in (m 2 /s)].

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2005

Magnetic and Electrical Characteristics of Cobalt-Based Amorphous Materials and Comparison to a Permalloy Type Polycrystalline Material

Magnetic component designers are always looking for improved soft magnetic core materials to increase the efficiency, temperature rating and power density of transformers, motors, generators and alternators, and energy density of inductors. In this paper, we report on the experimental investigation of commercially available cobalt-based amorphous alloys which, in their processing, were subjected to two different types of magnetic field anneals: A longitudinal magnetic field anneal or a transverse magnetic field anneal. The longitudinal field annealed material investigated was Metglas 2714A. The electrical and magnetic characteristics of this material were investigated over the frequency range of 1 to 200 kHz and temperature range of 23 to 150 C for both sine and square wave voltage excitation. The specific core loss was lower for the square than the sine wave voltage excitation for the same maximum flux density, frequency and temperature. The transverse magnetic field annealed core materials include Metglas 2714AF and Vacuumschmelze 6025F. These two materials were experimentally characterized over the frequency range of 10 to 200 kHz for sine wave voltage excitation and 23 C only. A comparison of the 2174A to 2714AF found that 2714AF always had lower specific core loss than 2714A for any given magnetic flux density and frequency and the ratio of specific core loss of 2714A to 2714AF was dependent on both magnetic flux density and frequency. A comparison was also made of the 2714A, 2714AF, and 6025F materials to two different tape thicknesses of the polycrystalline Supermalloy material and the results show that 2714AF and 6025F have the lowest specific core loss at 100 kHz over the magnetic flux density range of 0.1 to 0.4 Tesla.

Wieserman, William R.↗
DOE OSTI2025

Core Cartography

This is 200x microscope image of a cross section of a magnetic core.

Hines, Sydney Lynn [Sandia National Laboratories (↗
NASA NTRS1996

Dynamics of Permanent-Magnet Biased Active Magnetic Bearings

Active magnetic radial bearings are constructed with a combination of permanent magnets to provide bias forces and electromagnets to generate control forces for the reduction of cost and the operating energy consumption. Ring-shaped permanent magnets with axial magnetization are attached to a shaft and share their magnet stators with the electromagnets. The magnet cores are made of solid iron for simplicity. A simplified magnetic circuit of the combined magnet system is analyzed with linear circuit theory by approximating the characteristics of permanent magnets with a linear relation. A linearized dynamical model of the control force is presented with the first-order approximation of the effects of eddy currents. Frequency responses of the rotor motion to disturbance inputs and the motion for impulsive forces are tested in the non-rotating state. The frequency responses are compared with numerical results. The decay of rotor speed due to magnetic braking is examined. The experimental results and the presented linearized model are similar to those of the all-electromagnetic design.

Fukata, Satoru↗
DOE OSTI2021

Electromagnetic device having layered magnetic material components and methods for making same

A micro fabricated electromagnetic device and method for fabricating its component structures, the device having a layered magnetic core of a potentially unlimited number of alternating insulating and magnetic layers depending upon application, physical property and performance characteristic requirements for the device. Methods for fabricating the high performing device permit cost effective, high production rates of the device and its component structures without any degradation in device performance resulting from component layering.

Mehrotra, Vivek↗
DOE OSTI2015

Electrodeposited Nanolaminated CoNiFe Cores for Ultracompact DC-DC Power Conversion

Laminated metallic alloy cores (i.e., alternating layers of thin film metallic alloy and insulating material) of appropriate lamination thickness enable suppression of eddy current losses at high frequencies. Magnetic cores comprised of many such laminations yield substantial overall magnetic volume, thereby enabling high-power operation. Previously, we reported nanolaminated permalloy (Ni-80 Fe-20) cores based on a sequential electrodeposition technique, demonstrating negligible eddy current losses at peak flux densities up to 0.5 T and operating at megahertz frequencies. This paper demonstrates improved performance of nanolaminated cores comprising tens to hundreds of layers of 300-500-nm-thick CoNiFe films that exhibit superior magnetic properties (e.g., higher saturation flux density and lower coercivity) than permalloy. Nanolaminated CoNiFe cores can be operated up to a peak flux density of 0.9 T, demonstrating improved power handling capacity and exhibiting 30% reduced volumetric core loss, attributed to lowered hysteresis losses compared to the nanolaminated permalloy core of the same geometry. Operating these cores in a buck dc-dc power converter at a switching frequency of 1 MHz, the nanolaminated CoNiFe cores achieved a conversion efficiency exceeding 90% at output power levels up to 7 W, compared to an achieved permalloy core conversion efficiency below 86% at 6 W.

Kim, J↗
DOE OSTI2016

Frequency-Dependent Properties of Magnetic Nanoparticle Crystals

In the proposed research program we will investigate the time- and frequency-dependent behavior of ordered nanoparticle assemblies, or nanoparticle crystals. Magnetostatic interactions are long-range and anisotropic, and this leads to complex behavior in nanoparticle assemblies, particularly in the time- and frequency-dependent properties. We hypothesize that the high frequency performance of composite materials has been limited because of the range of relaxation times; if a composite is a dipolar ferromagnet at a particular frequency, it should have the advantages of a single phase material, but without significant eddy current power losses. Arrays of surfactant-coated monodomain magnetic nanoparticles can exhibit long-range magnetic order that is stable over time. The magnetic domain size and location of domain walls is governed not by structural grain boundaries but by the shape of the array, due to the local interaction field. Pores or gaps within an assembly pin domain walls and limit the domain size. Measurements of the magnetic order parameter as a function of temperature showed that domains can exist at high temoerature, and that there is a collective phase transition, just as in an exchange-coupled ferromagnet. Dipolar ferromagnets are not merely of fundamental interest; they provide an interesting alternative to exchange-based ferromagnets. Dipolar ferromagnets made with high moment metallic particles in an insulating matrix could have high permeability without large eddy current losses. Such nanocomposites could someday replace the ferrites now used in phase shifters, isolators, circulators, and filters in microwave communications and radar applications. We will investigate the time- and frequency-dependent behavior of nanoparticle crystals with different magnetic core sizes and different interparticle barrier resistances, and will measure the magnetic and electrical properties in the DC, low frequency (0.1 Hz - 1 kHz), moderate frequency (10 Hz - 500 MHz), and high frequency (up to 20 GHz) regimes. Our results will demonstrate whether a DC dipolar ferromagnet shows collective frequency-dependent reponse similar to that of an exchange-based ferromagnet, and will provide data for comparison of optimal nanocomposite properties with those of ferrites used in high frequency applications. Both the magnetic and electronic response of the composites will be examined in order to determine the frequency range where hopping conductivity leads to significant eddy current power losses. In the high frequency regime we will look for evidence of spin wave quantization and the resulting decrease in non-linear spin wave processes that could affect the performance of high frequency magnetic devices.

36 MATERIALS SCIENCE↗
NASA NTRS1981

Improved magnetic material analyzer

Flux-controlled magnetic-core-loss tester has been developed that produces high-frequency core-loss data (within 2 percent) for any desired waveform excitation and allows magnetic characteristics of material to be measured under symmetrical and asymmetrical excitation conditions. It allows direct control of additional loss variable rather than just driving frequency as is case for all previous sinusoidal core-loss measurements.

Triner, J. E.↗
NASA NTRS2001

H-alpha Proxies for EIT Crinkles: Further Evidence for Pre-Flare "Breakout"-Type Activity in an Ejective Solar Eruption

We present Halpha observations from Big Bear Solar Observatory of an eruptive flare in NOAA AR 8210, occurring near 22:30 UT on 1998 May 1. Previously, using the EUV Imaging Telescope (EIT) on the SOHO spacecraft, we found that a pattern of transient, localized brightenings, which we call "EIT crinkles," appears in the neighborhood of the eruption near the time of flare onset. These EIT crinkles occur at a location in the active region well separated from the sheared core magnetic fields, which is where the most intense features of the eruption are concentrated. We also previously found that high-cadence images from the Soft X-ray Telescope (SXT) on Yohkoh indicate that soft X-ray intensity enhancements in the core begin after the start of the EIT crinkles. With the Halpha data, we find remote flare brightening counterparts to the EIT crinkles. Lightcurves as functions of time of various areas of the active region show that several of the remote flare brightenings undergo intensity increases prior to onset of principle brightenings in the core region, consistent with our earlier findings from EIT and SXT data. These timing relationships are consistent with the eruption onset mechanism known as the breakout model, introduced by Antiochos and colleagues, which proposes that eruptions begin with reconnection at a magnetic null high above the core region. Our observations are also consistent with other proposed mechanisms which do not involve early reconnection in the core region. As a corollary, our observations are not consistent with the so-called tether cutting models, which say that the eruption begins with reconnection in the core. The Halpha data further show that a filament in the core region becomes activated near the time of EIT crinkle onset, but little if any of the filament actually erupts, despite the presence of a halo Coronal Mass Ejection (CME) associated with this event.

Sterling, Alphonse C.↗
NASA NTRS2001

H(alpha) Proxies for EIT Crinkles: Further Evidence for Preflare "Breakout"-Type Activity in an Ejective Solar Eruption

We present H(alpha) observations from Big Bear Solar Observatory of an eruptive flare in NOAA Active Region 8210, occurring near 22:30 UT on 1998 May 1. Previously, using the Extreme Ultraviolet Imaging Telescope (EIT) on the Solar and Heliospheric Observatory (SOHO) spacecraft, we found that a pattern of transient, localized brightenings, which we call 'EIT crinkles,' appears in the neighborhood of the eruption near the time of flare onset. These EIT crinkles occur at a location in the active region well separated from the sheared core magnetic fields, which is where the most intense features of the eruption are concentrated. We also previously found that high-cadence images from the Soft X-ray Telescope (SXT) on Yohkoh indicate that soft X-ray intensity enhancements in the core begin after the start of the EIT crinkles. With the H(alpha) data, we find remote flare brightening counterparts to the EIT crinkles. Light curves as functions of time of various areas of the active region show that several of the remote flare brightenings undergo intensity increases prior to the onset of principal brightenings in the core region, consistent with our earlier findings from EIT and SXT data. These timing relationships are consistent with the eruption onset mechanism known as the breakout model, introduced by Antiochos and colleagues, which proposes that eruptions begin with reconnection at a magnetic null high above the core region. Our observations are also consistent with other proposed mechanisms that do not involve early reconnection in the core region. As a corollary, our observations are not consistent with the so-called tether-cutting models, which say that the eruption begins with reconnection in the core. The H(alpha) data further show that a filament in the core region becomes activated near the time of EIT crinkle onset, but little if any of the filament actually erupts, despite the presence of a halo coronal mass ejection (CME) associated with this event.

Sterling, Alphonse C.↗
NASA NTRS1999

Wide Temperature Magnetization Characteristics of Transverse Magnetically Annealed Amorphous Tapes for High Frequency Aerospace Magnetics

100 kHz magnetization properties of sample transverse magnetically annealed, cobalt-based amorphous and iron-based nanocrystalline tape wound magnetic cores are presented over the temperature range of -150 C to 150 C, at selected values of B(sub peak). Frequency resolved characteristics are given over the range of 50 kHz to 1 MHz, but at B(sub peak) = 0.1 T and 50 C only. Basic exciting winding current and induced voltage data were taken on bare toroidal cores, in a standard type measurement setup. A linear permeability model, which represents the core by a parallel L-R circuit, is used to interpret and present the magnetization characteristics and several figures of merit applicable to inductor materials are reviewed. The 100 kHz permeability thus derived decreases with increasing temperature for the Fe-based, nanocrystalline material, but increases roughly linearly with temperature for the two Co-based materials, as long as B(sub peak) is sufficiently low to avoid saturation effects. Due to the high permeabilities, rather low values of the 'quality factor' Q, from about 20 to below unity, were obtained over the frequency range of 50 kHz to 1 MHz (50 C, B(sub peak) = 0.1 T). Therefore these cores must be gapped in order to make up high Q or high current inductors. However, being rugged, low core loss materials with flat B-H loop characteristics, they may provide new solutions to specialty inductor applications.

Niedra, Janis M.↗
NASA NTRS1999

Wide Temperature Characteristics of Transverse Magnetically Annealed Amorphous Tapes for High Frequency Aerospace Magnetics

100 kHz core loss and magnetization properties of sample transverse magnetically annealed, cobalt-based amorphous and iron-based nanocrystalline tape wound magnetic cores are presented over the temperature range of -150 to 150 C, at selected values of B(sub peak). For B-fields not close to saturation, the core loss is not sensitive to temperature in this range and is as low as seen in the best MnZn power ferrites at their optimum temperatures. Frequency resolved characteristics are given over the range of 50 kHz to 1 MHz, at B(sub peak) = 0.1 T and 50 C only. A linear permeability model is used to interpret and present the magnetization characteristics and several figures of merit applicable to inductor materials arc reviewed. This linear modeling shows that, due to their high permeabilities, these cores must he gapped in order to make up high Q or high current inductors. However, they should serve well, as is, for high frequency, anti ratcheting transformer applications.

Niedra, Janis M.↗
NASA NTRS2008

CME-Producing Precursors to the 2006 December 13 X-Flare

We revisit one of the largest explosions observed during the Hinode era, the X4.3 class event of 2006 Dec 13. We gain insight into the main eruption through study of two sub-C-class precursor eruptions, occurring within 12 hours of and originating from the same (or nearby) neutral line as the X-flare. The precursors share some features in common with the main eruption, and their lower energy and consequent slower development renders interpretation of these features easier to decipher than in the rapidly explosive main eruption. In addition, because the weak precursors occurred in a magnetically strong region, magnetic connections indicated by soft X-ray loops are readily visible in these cases, while such connections can be much less apparent in weaker-region eruptions. Hinode/SOT magnetograms indicate that photospheric magnetic dynamic activity in the "magnetic core" is the likely ultimate source of the eruptions. All the eruptions, however, produce Coronal Mass Ejections (CMEs) that have wider spatial extent than the localized source region; this is a long-observed but puzzling phenomena, which can address directly here using the high-quality Hinode data. For the precursor eruptions, Hinode/XRT images show that the initial eruptions occur inside larger-scale magnetic structures that encompass the core. The exploding core field blows out this larger-scale structure, resulting in the CME having angular extent far exceeding that of the source-region core alone; this is the arch-arch-blowout scenario for CMEs of Moore & Sterling (2007). Similar processes occur in the main eruption, except that the much larger energy release in that eruption compared to the precursors results in much faster and larger-scale phenomena.

Sterling, Alphonse C.↗
DOE OSTI2017

Evidence of Formation of Superdense Nonmagnetic Cobalt

Because of the presence of 3d transition metals in the Earth’s core, magnetism of these materials in their dense phases has been a topic of great interest. Theory predicts a dense face-centred-cubic phase of cobalt, which would be nonmagnetic. However, this dense nonmagnetic cobalt has not yet been observed. Recent investigations in thin film polycrystalline materials have shown the formation of compressive stress, which can increase the density of materials. We have discovered the existence of ultrathin super-dense nonmagnetic cobalt layers in a polycrystalline cobalt thin film. The densities of these layers are about 1.2–1.4 times the normal density of Co. This has been revealed by X-ray reflectometry experiments, and corroborated by polarized neutron reflectometry (PNR) experiments. Transmission electron microscopy provides further evidence. The magnetic depth profile, obtained by PNR, shows that the super-dense Co layers near the top of the film and at the film-substrate interface are nonmagnetic. The major part of the Co film has the usual density and magnetic moment. These results indicate the possibility of existence of nonmagnetic Co in the earth’s core under high pressure.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗