Fatigue properties of AL/AL-MG alloy laminated materials for the applications to railway tank cars
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Yang, Guangxue↗
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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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Insulation or Irradiance: Exploring Why Bifacial Photovoltaics Run Hot
Bifacial photovoltaics are predicted to become the dominant device architecture over the next couple of years, but their thermal performance is not yet well understood. In this study, we model the thermal effects of different backside lamination materials on the performance of bifacial PERC cells. Glass-glass laminated cells were found to operate hotter than equivalent glass-polymer backsheet packed cells. This was solely due to the increased absorption of rear side incident light.
bifacial↗
Laminated magnetic materials for on-chip magnetic inductors/transformers
A technique relates to a method of forming a laminated multilayer magnetic structure. An adhesion layer is deposited on a substrate. A magnetic seed layer is deposited on top of the adhesion layer. Magnetic layers and non-magnetic spacer layers are alternatingly deposited such that an even number of the magnetic layers is deposited while an odd number of the non-magnetic spacer layers is deposited. The odd number is one less than the even number. Every two of the magnetic layers is separated by one of the non-magnetic spacer layers. The first of the magnetic layers is deposited on the magnetic seed layer, and the magnetic layers each have a thickness less than 500 nanometers.
36 MATERIALS SCIENCE↗
Laminated magnetic materials for on-chip magnetic inductors/transformers
A technique relates to a method of forming a laminated multilayer magnetic structure. An adhesion layer is deposited on a substrate. A magnetic seed layer is deposited on top of the adhesion layer. Magnetic layers and non-magnetic spacer layers are alternatingly deposited such that an even number of the magnetic layers is deposited while an odd number of the non-magnetic spacer layers is deposited. The odd number is one less than the even number. Every two of the magnetic layers is separated by one of the non-magnetic spacer layers. The first of the magnetic layers is deposited on the magnetic seed layer, and the magnetic layers each have a thickness less than 500 nanometers.
36 MATERIALS SCIENCE↗
Experimental characterization and modeling of thermal resistance of electric machine lamination stacks
There is lack of information in the open literature on thermal properties of electric machine lamination stacks such as contact resistance and effective thermal conductivity, yet this information is critical for researchers and engineers in electric machine design and development. The thermal conductivity of electromagnetic steel lamination materials was measured, and the thermal contact resistance between laminations in a stack, as well as factors affecting contact resistance between laminations - such as the contact pressure and surface finish - were investigated. A model was also developed to estimate the through-stack thermal conductivity for materials beyond those that were directly tested in this work. Four lamination materials were investigated, including the commonly-used 26-gauge and 29-gauge M19 materials, the HF10, and Arnon 7 materials. Although this paper focuses on electric machines for automotive applications, the information is potentially applicable to any component utilizing electromagnetic steel laminations.
30 DIRECT ENERGY CONVERSION↗
Improving energy yield in photovoltaic modules with photonic structures
When installed outdoors, Si solar cells typically operate 20 – 30 K above ambient conditions. These elevated operating temperatures lead to diminished performance, reducing efficiency by ~0.4%/K for crystalline Si cells and decreasing module lifetime. Since much of the elevated temperature of the modules derives from parasitic absorption of sub-bandgap sunlight by the contacts, encapsulants, or other materials, reflectors that remove the sub-bandgap radiation from the module before it is absorbed promise to reduce the operating temperature. However, there are many competing strategies to reject this light: selective reflectors could be integrated into the outer module glass, at the textured Si-encapsulant interface, or on the rear. Furthermore, many of these approaches are complex and expensive to fabricate. The issue of heating can be even more critical in bifacial modules: high fractions of rear irradiance can lead to higher operating temperatures. Prior to this project, relatively little was known about the optical strategies for temperature reduction in bifacial modules. The goal of this project was to quantitatively assess optical strategies for improving the energy yield via a combination of improved anti-reflection and sub-bandgap light rejection. We studied two complementary concepts: the performance of ideal structures to determine the upper limits to performance, and low-complexity structures made from standard materials as cost-effective implementations. We also studied the performance of these reflectors in different types of modules, including Al BSF, PERC, and bifacial. Here we build from our prior accomplishments in developing mirror optimization techniques, and make use of simulation methods that accurately capture the optical properties of the modules throughout the visible and near-infrared spectrum. We connect these optical properties to energy yield under realistic, outdoor conditions. We also experimentally fabricated mirrors, incorporated them into mini-modules, and performed outdoor testing of performance at NREL. We found definitively that spectrally-selective mirrors on the outside of the module cover glass offer the best performance, both under ideal conditions and for realistic, low- complexity mirrors. Mirrors at the Si cell/encapsulant interface are limited by the multiple reflections needed to remove sub-bandgap light. Mirrors at the cell surface and mirrors on the rear also cannot remove all the sub-bandgap light, since parasitic absorption also occurs in the cover glass, encapsulant, and front contacts, depending on the module configuration. Also, cell texturing places higher demands on any cell-surface mirror because multiple interactions with the mirror are required to reject sub bandgap light which compounds losses. For bifacial modules, mirrors on the back do provide additional cooling and energy yield improvements, and the mirrors can have the same structure. In the monofacial case up to 3.3K of cooling is possible for mirrors on the front, compared to 2.2K at the cell surface and 1.2K at the rear. For bifacial modules, up to 2.4K of cooling is possible when mirrors are included at both the front and back. Our realistic designs utilize 4 – 6 layers of common photovoltaic materials such as SiO 2 , TiO 2 , and SiN x , making them more cost effective. Finally, we used our models to study thermal management in bifacial modules with different back lamination materials, finding that glass-glass laminated modules operated hotter than equivalent glass-polymer backsheet modules, due solely to the increased absorption of light incident from the rear of the module. Improving the energy yield by 2%, which is achievable with these realistic designs, would lead to LCOE reductions of $0.03/kWh by 2030. These benefits make photovoltaic panels more accessible to the public and may reduce associated maintenance costs.
14 SOLAR ENERGY↗
Electric Motor Thermal Management for Electric Traction Drives (Presentation)
Thermal constraints place significant limitations on how electric motors ultimately perform. Finite element analysis and computational fluid dynamics modeling approaches are being increasingly utilized in the design and analysis of electric motors. As the models become more sophisticated, it is important to have detailed and accurate knowledge of material thermal properties and convective heat transfer coefficients. In this work, the thermal properties and inter-lamination thermal contact resistances were measured for different stator lamination materials. Also, convective heat transfer coefficients of automatic transmission fluid (ATF) jets were measured to better understand the heat transfer of ATF impinging on motor copper windings. Experiments were carried out at various ATF temperatures and jet velocities to quantify the influence of these parameters on heat transfer coefficients.
30 DIRECT ENERGY CONVERSION↗
Microstructure Reconstruction of Sheet Molding Composite Using a Random Chips Packing Algorithm
Fiber-reinforced polymer composites are strong candidates for structural materials to replace steel and light alloys in lightweight vehicle design because of their low density and relatively high strength. In the integrated computational materials engineering (ICME) development of carbon fiber composites, microstructure reconstruction algorithms are needed to generate material microstructure representative volume element (RVE) based on the material processing information. The microstructure RVE reconstruction enables the material property prediction by finite element analysis (FEA)This paper presents an algorithm to reconstruct the microstructure of a chopped carbon fiber/epoxy laminate material system produced by compression molding, normally known as sheet molding compounds (SMC). The algorithm takes the result from material’s manufacturing process as inputs, such as the orientation tensor of fibers, the chopped fiber sheet geometry, and the fiber volume fraction. The chopped fiber sheets are treated as deformable rectangle chips and a random packing algorithm is developed to pack these chips into a square plate. The RVE is built in a layer-by-layer fashion until the desired number of lamina is reached, then a fine tuning process is applied to finalize the reconstruction. Compared to the previous methods, this new approach has the ability to model bended fibers by allowing limited amount of overlaps of rectangle chips. Furthermore, the method does not need SMC microstructure images, for which the image-based characterization techniques have not been mature enough, as inputs. Case studies are performed and the results show that the statistics of the reconstructed microstructures generated by the algorithm matches well with the target input parameters from processing.
Huang, Tianyu↗
Electric machine stator lamination with dual phase magnetic material
A stator lamination for an electric machine has a circular lamination with an annular bore therethrough; winding slots therethrough; and, slot closures disposed adjacent to the winding slots. The stator lamination is formed of a dual magnetic phase material, such that the magnetic property of the lamination can have a first state and a magnetic property in a second state, wherein the second state is different than the first state. The slot closures regions are treated so as to transition to the second state. A method of manufacturing an electric machine component is also disclosed.
Galioto, Steven Joseph↗
The Influence of PV Module Materials and Design on Solder Joint Thermal Fatigue Durability
Finite element model (FEM) simulations have been performed to elucidate the effect of flat plate photovoltaic (PV) module materials and design on PbSn eutectic solder joint thermal fatigue durability. The statistical method of Latin Hypercube sampling was employed to investigate the sensitivity of simulated damage to each input variable. Variables of laminate material properties and their thicknesses were investigated. Using analysis of variance, we determined that the rate of solder fatigue was most sensitive to solder layer thickness, with copper ribbon and silicon thickness being the next two most sensitive variables. By simulating both accelerated thermal cycles (ATCs) and PV cell temperature histories through two characteristic days of service, we determined that the acceleration factor between the ATC and outdoor service was independent of the variables sampled in this study. This result implies that an ATC test will represent a similar time of outdoor exposure for a wide range of module designs. This is an encouraging result for the standard ATC that must be universally applied across all modules.
14 SOLAR ENERGY↗
Electric Motor Thermal Management R&D (Presentation)
Thermal constraints place significant limitations on how electric motors ultimately perform. Without the ability to remove heat, the motor cannot operate without sacrificing performance, efficiency, and reliability. Finite element analysis and computational fluid dynamics modeling approaches are being increasingly utilized in the design and analysis of electric motors. As the models become more sophisticated, it is important to have detailed and accurate knowledge of both the passive thermal performance and the active cooling performance. In this work, we provide an overview of research characterizing both passive and active thermal elements related to electric motor thermal management. To better characterize the passive thermal performance, the effective thermal properties and inter-lamination thermal contact resistances were measured for different stator lamination materials. The active cooling performance of automatic transmission fluid (ATF) jets was also measured to better understand the heat transfer coefficients of ATF impinging on motor copper windings. Ford's Mercon LV was the ATF evaluated in this study. The presentation provides an overview of prior work with a focus on describing future plans for research to be performed during FY15.
33 ADVANCED PROPULSION SYSTEMS↗
A peridynamic failure analysis of fiber-reinforced composite laminates using finite element discontinuous Galerkin approximations
Here, this paper presents a discontinuous Galerkin weak form for bond-based peridynamic models to predict the damage of fiber-reinforced composite laminates. To represent the anisotropy of a laminate in a peridynamic model, a lamina is simplified as a transversely isotropic medium under a plane stress condition. The laminated structure is modeled by stacking the surface mesh layers along the thickness direction according to the laminate sequence. To avoid a mesh dependence on either the fiber orientation or the discretization, the spherical harmonic expansion theory is employed to construct a function for the micro-elastic modulus in terms of the bond-fiber angle. The laminate material is decomposed into an isotropic matrix material part and a transversely isotropic material part. The bond stiffness can be evaluated using the engineering material constants, based on the equivalence between the elastic energy density in the peridynamic theory and the elastic energy density in the classic continuum mechanics theory. Benchmark tests are conducted to verify the proposed model. Numerical results illustrate that the convergence of simulations with different horizon sizes and meshes can be achieved. In terms of damage analysis, the proposed model can capture the dynamic process of the complex coupling of the inner-layer and delamination damage modes.
42 ENGINEERING↗
Autophagy induction in tobacco leaves infected by potato virus Y{sup O} and its putative roles
Autophagy plays a critical role in the innate immune response of plants to pathogen infection. In the present study, we examined autophagy induced by potato virus Y ordinary strain (PVY{sup O}) infection in tobacco (Nicotiana benthamiana). Enzyme-linked immunosorbent assays revealed that the number of virus particles in the plant peaked at 2 weeks post-inoculation and then gradually decreased. Additionally, the amount of virus increased significantly in the 3rd and 4th leaves distal to the inoculated leaf and decreased slightly in the 5th leaf. Within 2 weeks of PVY{sup O} inoculation, the tobacco leaves showed typical symptoms of Potyvirus inoculation, including mottling, yellowing, a mosaic pattern, and necrotic tissue changes at the inoculated site. Based on an ultrastructural analysis of the PVY{sup O}-infected tobacco leaves, virus aggregates appeared as longitudinal and transverse arrays and pinwheels, which are typical of Potyvirus inoculation. Moreover, PVY{sup O} infection caused changes in the number, size, and shape of chloroplasts, whereas the number of plastogranules increased markedly. Furthermore, double-membrane autophagosome-like vacuoles, including electron-dense materials, laminated structures, and cellular organelles, were found. The induction of autophagy after the PVY{sup O} infection of tobacco leaves was further confirmed by the expression of lipidated microtubule-associated protein 1 light chain 3 (LC3)-II, an autophagy marker and p62, an autophagy adaptor protein. The LC3-II levels increased daily over the 4-week period. Although virus inoculation was performed systemically on the basal leaves of the plants, LC3-II was expressed throughout the leaves and the expression was higher in leaves distal to the inoculated leaf. Moreover, PVY{sup O} infection caused the activation of stress-activated protein kinases/c-Jun N-terminal kinases. Therefore, PVY{sup O} infection-induced autophagy was positively correlated with the virus content, suggesting that autophagy induction following PVY{sup O} infection is involved in the anti-pathogen response of the host. -- Highlights: •The amount of PVY{sup O} revealed a peak at 2 weeks post-inoculation. •The amount of PVY{sup O} was higher in leaves distal to the inoculated leaf. •PVY{sup O} infection produced typical PVY infection symptoms. •Double-membranous vacuoles, including cellular organelles, were induced by PVY{sup O} infection. •PVY{sup O} infection induced LC3-II and JNK activation.
60 APPLIED LIFE SCIENCES↗
Hydroquinone-ZnO nano-laminate deposited by molecular-atomic layer deposition
In this study, we have deposited organic-inorganic hybrid semiconducting hydroquinone (HQ)/zinc oxide (ZnO) superlattices using molecular-atomic layer deposition, which enables accurate control of film thickness, excellent uniformity, and sharp interfaces at a low deposition temperature (150 °C). Self-limiting growth of organic layers is observed for the HQ precursor on ZnO surface. Nano-laminates were prepared by varying the number of HQ to ZnO cycles in order to investigate the physical and electrical effects of different HQ to ZnO ratios. It is indicated that the addition of HQ layer results in enhanced mobility and reduced carrier concentration. The highest Hall mobility of approximately 2.3 cm{sup 2}/V·s and the lowest n-type carrier concentration of approximately 1.0 × 10{sup 18}/cm{sup 3} were achieved with the organic-inorganic superlattice deposited with a ratio of 10 ZnO cycles to 1 HQ cycle. This study offers an approach to tune the electrical transport characteristics of ALD ZnO matrix thin films using an organic dopant. Moreover, with organic embedment, this nano-laminate material may be useful for flexible electronics.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Impact of Ultra-Conducting Winding on the Power Density and Performance of Non-Heavy Rare Earth Traction Motors
The emergence of carbon nanotube-copper composite conductors has opened a new degree of freedom in the electric machine design to improve the machine's performance: the conductivity of the winding. The goal of the present study is: 1) to determine how much improvement in power per unit volume and performance can be achieved with the increase in winding conductivity; and 2) to investigate any physical limitations on the effectiveness of this degree of freedom in improving the power per unit volume and performance of electric traction motors. Conventional electric motor topologies affected by ferromagnetic saturation as well as slotless topology that is not affected by saturation are analyzed. It was found that the ferromagnetic saturation of the lamination materials reduces the effectiveness of highly conductive winding in improving the power per unit volume. For machine topologies that are not affected by ferromagnetic saturation, the power density improvement reaches the theoretical expectation. In both cases, highly conductive winding improves the efficiency map by enlarging high efficiency operating area into light load as well as high speed operations.
Raminosoa, Tsarafidy↗
Soft Magnetic Multilayered FeSiCrB–Fe$_{x}$N Metallic Glass Composites Fabricated by Spark Plasma Sintering
Novel multilayered FeSiCrB–Fe $_{x}$ N ( x = 2–4) metallic glass composites were fabricated using spark plasma sintering of FeSiCrB amorphous ribbons (Metglas 2605SA3 alloy) and Fe $_{x}$ N ( x = 2–4) powder. Crystalline Fe $_{x}$ N can serve as a high magnetic moment, high electrical resistance binder, and lamination material in the consolidation of amorphous and nanocrystalline ribbons, mitigating eddy currents while boosting magnetic performance and stacking factor in both wound and stacked soft magnetic cores. Stacking factors of nearly 100% can be achieved in an amorphous ribbon/iron nitride composite. FeSiCrB–Fe $_{x}$ N multilayered metallic glass composites prepared by spark plasma sintering have the potential to serve as a next-generation soft magnetic material in power electronics and electrical machines.
36 MATERIALS SCIENCE↗
Cost Effective 6.5% Silicon Steel Laminate for Electric Machines
Iowa State University teamed with United Technologies Research Center and the University of Delaware and demonstrated a high switching frequency non-rare earth permanent magnet motor. A prototype motor with 400 Hz switching frequency, dummy MnBi permanent magnet with 8 MGOe energy density, and 6.5%Si steel as the laminate materials was designed, built, and tested. The performance of the prototype met the expectations showing a higher frequency motor enabled by 6.5%Si steel is a viable approach to meet DOE 2022 cost and performance targets for electric vehicle drive. Adoption of 6.5%Si steel will result in 3% improvement in energy conversion efficiency of the soft magnetic materials. In addition, the ability to use non-rare earth magnet for high power density application effectively mitigate the risk of EV traction motor from the rising rare earth price.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Non-Destructive Evaluation of the Bondline Interface between Carbon Fiber Reinforced Laminated Composites and Metal Materials via Ultrasonic Inspection Methods
Woven fiber, laminated composites allow the design engineer to create high strength parts, but the effectiveness of the final processed part is greatly diminished through weak or nonexistent bonds between the composite and the substrate to which it is bonded. Additionally, these layered laminates are commonly made by curing the resin infused carbon fiber fabrics in predefined layers and then bonding them to another composite or a metallic structure using either a pre-cure or a co-cure method. The focus of this study is the identification of the defect caused by a disbond or a delamination located at the interface between a composite laminate stack and the substrate to which it is bonded. We present a nondestructive approach using various ultrasonic methods to identify the existence of the bond between composite and composite-to-metal interface. This paper explores contact and immersion ultrasound methods using pulse-echo for evaluating the composite material and adhesive bondline and the signal attenuation undergone by the wave as it propagates through the composite. Finally, a summary of the detection and analysis techniques developed to identify disbonds, including Fast Fourier Transform analysis of the immersion data, is presented. Lastly, each of the methods evaluated in this study is able to detect the transition from bonded to unbonded sections at the bondline from either side of the bonded part, with the immersion technique providing a significantly higher resolution of the edge of the bondline.
36 MATERIALS SCIENCE↗