Nanostructured and Nanocomposite Material Enabled Devices for Electrical Systems Presenter : Dr. Paul R. Ohodnicki, Jr. Electric Power Industry Conference October 15, 2018
Solutions for Today | Options for Tomorrow
Presentation Overview • Motivation for Materials Enabled Device Research and Development • Soft Magnetic Materials and Components for Power Conversion Applications • DOE EERE Advanced Manufacturing Office NGEM Programs • Inductors for Next Generation Motor Drives (NGEM-1)
• DOE EERE SuNLaMP Program • Three-Port DC-DC Converter for Combined PV and ES Integration • Advanced Materials Development and Transformer Designs
• DOE OE Transformer Reliability and Advanced Components • Detailed Magnetic Core Characterization • Advanced Magnetic Component Modeling and Optimization Techniques
• Optical Fiber Based Sensors for Electrical Asset Monitoring • DOE GMLC Advanced Sensor Development Project • Low-Cost H2 / T Sensors • Multipoint Temperature Sensors
• Summary and Concluding Remarks National Energy Technology Laboratory
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The “New” Materials Science Paradigm Classic Materials Science Paradigm
Emerging Paradigm Materials Interface with Functional Systems and Devices Opportunities for Innovation Exist at the “Interface” Between New Functional Materials and Advanced Components. Challenge = Effectively Bridge Gap Between Materials Research and Component Optimization
Engineering of Functional Materials for Specific Device and System Level Functionality Imposes Unique Constraints and Opportunities. National Energy Technology Laboratory
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What is a “Nanocomposite” Material? Example: Nanocrystals Embedded in a Continuous Intergranular Phase
Structural Features are Similar or Below Characteristic Fundamental Lengths: Ferromagnetic Exchange Lengths Mean Free Path of Electronic Carriers
Nanocrystals
Mean Free Path of Phonons
Intergranular Phase
Visible Light Wavelengths Result = Unique, Tunable Optical, Magnetic, and Electronic Properties
A “Nanocomposite” is Defined by Having Multiple Phases Intermixed on at Least One Characteristic Length Scale Less than Approximately 100nm. National Energy Technology Laboratory
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Soft Magnetic Material Enabled Components Solid State Transformers
Power Electronics Converters
Higher Efficiency Distribution Transformers
ARPA-E
Electrical Machinery and Drives Soft magnets
More than 80% of Electricity is Projected to Flow Through Power Electronics By 2030
Coils Permanent magnets
Grid Modernization, Electrification, Shifts Towards Distributed Generation Resources, Higher Efficiency and More Flexible Transformer Technologies National Energy Technology Laboratory
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Research Collaborations in Soft Magnetics Amorphous and Nanocomposite Alloy Development & Scale-Up
Application Relevant Performance Testing and Characterization
Nanocrystals
Intergranular Phase
Manufacturing Scale Processing Including Core Fabrication and Processing
b)
Component Scale Electromagnetic Modeling and Testing
c)
Core Fabrication and Testing, Process Flow Diagram
Core Field Distribution
Winding Field Distributio
A Basic Set of Capabilities and Collaborations are Being Leveraged Across a Broad Range of e) Projects to Address Challenges in the Area of Advanced Soft Magnetic Materials
.10. (a) Figure of A 15kW, 30kHz power inductor employing a cut-core and (b) corresponding thermal g operation showing “hot-spots” at gap locations. (c) Comparable “ungapped” core fabricated using stress to tune permeability and eliminate hot-spots / fringing fluxes. (d) High surface quality of cores for the HF er in a 100kW, 50kHz DC-DC converter (e) developed under a recent ARPA-E Solar ADEPT project.
National Energy Technology Laboratory
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Metal / Amorphous Nanocomposite Synthesis
Nanocrystals
Intergranular Phase
Large-Scale Planar Flow Casting Facility Demonstration for Alloy Scale-Up Efforts
Pilot Scale Caster Up to 1-2� Ribbon Widths
National Energy Technology Laboratory
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Alloy Classes Under Investigation Across Programs Composition Optimization for Mechanical Properties “Fe- Based Alloys”
Improvements in Permeability Engineering Through Processing
Alloy Composition Engineering for Core Level Properties
Annealing Profile Optimization
“Co-Based Alloys”
“FeNi-Based Alloys”
Optimizing Responses to Field and Strain Annealing
A Number of New Alloy Classes are Being Explored and Further Optimized for High Frequency Transformer Based Power Conversion Applications. National Energy Technology Laboratory
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Pilot Scale Field and Strain Annealing Facilities In-Line Strain Annealing System
Transverse Field Annealing System
Strain Annealing Line for Applied Tension Anneals of Tape Wound Core Ribbons and Transverse Field Annealer for Tuning of Permeability and Optimization of Soft Magnetic Properties. National Energy Technology Laboratory
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Filter Inductors for MW-Scale Motor Drives Strain and Field Annealing to Achieve Lower Permeability Cores for Inductor Applications
e.g. Eliminate Gapping
a)
a) b)
b)
c)
c)
Reduced Stray Fields:
1) Reduced Electromagnetic Interference 2) Reduced Proximity Losses in Windings
Development and Demonstration of Advanced Soft Magnetic Alloy Cores in Filter Inductors Leveraging Advanced Processing Strategies for MW-Scale Motor Drives. National Energy Technology Laboratory
d)
d)
e)
e)
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Strain Annealed Co-Based Nanocomposites “Sheared Loop” with Unprecedented Low Permeabilities Achievable!
Structural Characterization Shows Close-Packed Crystallites
Characteristic Planar Faults Biased Through Applied Stress
“Square Loop” with High Relative Permeability
Current Project Work Targets Development and Demonstration of Co-Based Alloy Cores in Filter Inductors Leveraging Advanced Processing Strategies for MW-Scale Motor Drives. A. Leary, V. Keylin, A. Devaraj, V. DeGeorge, P. Ohodnicki, and M. E. McHenry, National Energy Technology Journal of Materials Research 31 (20), 3089-3107 (2016). Laboratory
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Latest Advances : Wide Strips and New Alloys Successful 2” Wide Strain Anneal and A Range of Permeabilities Attainable GRC 52 Perm vs Tension (1kA/m)
Mass = 10kg, L=400mH Full-Scale Filter Inductor
GRC 55 Perm vs Tension (1kA/m)
70.0
300.0
60.0 Permeability
Permeability
250.0 200.0 150.0 100.0 50.0 Beg Set
50.0 40.0 30.0
20.0 10.0
End Set
0.0
Beg Set
End Set
0.0 0
50
100
150
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Tension, MPa
50
100
150
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Tension, MPa
GRC 55 Perm vs Tension (1kA/m)
GRC 52 Perm vs Tension (1kA/m)
0
70.0
300.0
60.0 Permeability
Permeability
250.0 200.0 150.0 100.0 50.0 Beg Set
50.0 40.0 30.0
20.0 10.0
End Set
0.0
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End Set
0.0 0
50
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Tension, MPa
300
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50
100
150
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Tension, MPa
We Have Recently Demonstrated Successful Casting and Strain Annealing of 2” Wide Strip CoBased Alloys for Lengths Large Enough for Core Fabrication and Testing. National Energy Technology Laboratory
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In-Line Strain Annealing to Locally Optimize Properties
Drive Rollers
Unwind Spool
Rewind spool
Real-time controller
Thermal annealing furnace
Strain Annealing is a Key Processing Technique Being Leveraged in Advanced Alloy and Core Design and Optimization, Including Locally Varying Core Properties for Optimal Performance. National Energy Technology Laboratory
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Permeability Engineered Co-Based Nanocomposites Examples of Permeability Engineered Magnetic Cores Tunable
µ
µ
Ribbon Length
Tunable
Cyclic
Graded
µ
Experimental Thermal Profile : IR Camera
Ribbon Length
Graded
Ribbon Length
Cyclic
Finite Element Simulations of Thermal Profile K. Byerly et al., Journal of Materials Research 2018 In Press.
Control Over Tension as a Function of Annealing Time Enables Heterogeneous Permeability Cores with Optimized Properties for (1) Losses and (2) Thermal Performance Amongst Others. National Energy Technology Laboratory
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Three-Port DC-DC Converter Technology
Nanocomposite Soft Magnets Overall PV / ES Inverter System Nanocrystals
Three-Port Modular DC-DC Converter
Intergranular Phase
3-Limb Nanocomposite Core Transformer
a)
b)
Wide-Bandgap Based Power Electronics Converters are Being Integrated with High converter Frequency Figure III.6. PV and ESS Integration module connec Figure III.3. Three Limb PV-Energy Storage Integrated DC-DC (left) and DC-AC converter module (right). 3-phase grid integration using (a) DC-DC modules in a series c DC-AC modules in a cascading inverter topology. Transformer Technology for Combined PV and ES Integration. National Energy Technology Laboratory
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Enabling Technology: Multi-winding HF Transformers Transformer Architecture
A Three-Port Transformer is a Key Enabling Technology For the Topology
Constituent Core Materials
Winding Design (# of Turns, Geometry, etc)
The Multi-winding High Frequency Transformer is a Key Enabling Technology Benefiting From Advances in (1) Core Materials, (2) Magnetic Core Engineering, and (3) Transformer Design. National Energy Technology Laboratory
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Engineered Fe-Based Nanocomposite Transformers Original Designs :
Final Designs :
Traditional 3-Winding Transformer Core
3-Winding Concentric or ShellType Transformer Design
100x Greater Leakage Flux losses!
Fe-Based Nanocomposite Cores Were Essential for Successfully Achieving Required Project Milestones at 50kW Level and Detailed Understanding of Electromagnetics was Required. National Energy Technology Laboratory
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New Optimization Approaches for Advanced Cores Multi-Objective Genetic Algorithm Design Optimization
Solutions for Flux Distribution Throughout the Magnetic Core
Full Core Performance Predictions Through Analytical and Finite Element Models
Advanced Magnetic Core Models are Being Integrated into Genetic Algorithm Based Optimization Packages to Enable “Permeability� Engineered Core Optimization. National Energy Technology Laboratory
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Standardized Magnetic Core Characterization https://www.netl.doe.gov/research/on-site-research/publications/featured-technical-reports
Systematic Core Loss Measurements are Being Performed as a Function of Excitation Waveform for Custom and Commercially Available Cores as a Resource for the Community. National Energy Technology Laboratory
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Optical Fiber Based Sensing Technology MODEL
COST
Market interest
< $100-$300
Serveron TM1 Single Gas On-line Dissolved Gas Monitor
$6,500-7,500
MTE HYDROCAL
$8,565
LumaSense SmartDGA for Transformers
$15,000-25,000
Serveron On-line Gas Chromatography Dissolved Gas Monitor
$25,000-45,000
GE Kelman analysers
$46,800
Camlin Power TOTUS DGA
$40,000
Qualitrol Fiber Optic Temperature Monitor
$5,000-16,000
Transformer Advantage Advanced Electronic Temperature Monitor
$4,000
IntelliSAW IS485 SAW temperature sensors
$3,000
Neoptix T/Guard fiber optic temperature sensor
$10,000
Low-Cost Sensors Enable Asset Health Monitoring of a Broader Range of Electrical Assets. Chemical Sensing Strategies for Real-Time Monitoring of Transformer Oil: A Review, NationalIEEE Energy Technology C Sun, PR Ohodnicki, EM Stewart, Sensors Journal 17 (18), 5786-5806 Laboratory
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Au- and Pd-Nanocomposite Based H2 / T Sensors Au
Pd
Discrete-wavelength interrogation Enables low cost multi-parameter sensors ➢ temperature between ambient to 110 ºC
5–30 nm noble metal NPs ➢ H2 between 100 to 2000 ppm at RT
• • • •
Pd/SiO2 and Au/SiO2 nanocomposites Zeolitic filter overlayers to improve selectivity Pd/SiO2 selective to H2 Au/SiO2 selective to temperature
Low-Cost Fiber Optic Sensor Array for Simultaneous Measurement of Temperature and H2. National Energy Technology Laboratory
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Prototype Sensor Cost Reduction â&#x2013;Ş Low-cost components have been developed to generate robust sensing signals â&#x2013;Ş Potential applications exist for economical deployment in transformer monitoring systems
DH-2000-BAL light source
Green (530 nm) Mounted HighPower LED
T-Cube LED Driver with Trigger Mode
LED circuit
Fiber optic sensor
Fiber optic sensor
Fiber optic sensor
JAZ spectrometer
Standard Photodiode Power Sensors, 200-1100 nm
Si Photodiode circuit
Digital Optical Power and Energy Meter
Setup
Cost
Deuterium halogen source + spectrometer
$12,000
Mounted LED + power meter
$2,100
Unmounted LED + photodiode circuit
~$100
Cost Reductions Pursued Over the Project are Approaching Commercially Relevant Targets. National Energy Technology Laboratory
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Quantum Dot Enabled Multipoint Temp. Sensing Core Technology Details
Efficient Optical Excitation of QD
Random Hole Fibers
Quantum Dot Infiltration
Leverage Inherent Temperature Dependence
Optical Fiber Sensor Technology Based on Quantum Dots and Porous Random Air Hole Fibers. National Energy Technology Laboratory
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Fiber Bundle Approach to Reduce Cost Per Sensor Core Technology Details Blue LED Excitation
Fiber Bundle for Multipoint Sensing Red QD Emission
A Bundled Fiber Array Combined with a CCD Detector Enables Low Cost Interrogation. National Energy Technology Laboratory
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Field Validation Efforts for Packaged Optical Sensors Packaged, Portable Prototype Development Status
Instrumented Transformer Core
Fully Packaged Optical Components Communications PCB Control PCB
⑦
①
Estimated Cost < $10 / Sensor Node
⑧
②
③ ④
⑤
⑥
Optical Fiber Sensor Array to Distribution Assets
Thermal Image Sensor Signals
Prototypes Have Been Developed at High TRL and Demonstrated on Instrumented Cores. National Energy Technology Laboratory
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Key Take-Away Messages •
Advanced Nanostructured and Nanocomposite Materials Can Be Integrated Into Advanced Components • Enhanced Performance or Functionality • Reduced Cost and Device Simplicity
•
Soft Magnetic Amorphous / Nanocrystalline Nanocomposites • Strain Annealed Inductor Cores • Heterogeneous Permeability Engineering • Advanced Transformer Designs • New Optimization Methods and Systematic Core Characterization Nanocrystals
•
Optical Fiber Sensors Integrated with Nanomaterials and Nanocomposites • Combined H2 and Temp. Sensing at Low Cost • Multi-point Temperature Sensing
•
A Significant Patent Portfolio Has Been Established for Licensing and We Are Always Looking for Collaborators National Energy Technology Laboratory
Intergranular Phase
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Acknowledgements and Disclaimer Project Partners
Sponsors Contact Information: Dr. Paul R. Ohodnicki, Jr. Paul.Ohodnicki@netl.doe.gov Office: 412-386-7389
This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
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