Paul Ohodnicki Jr EPIC 2018

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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What is the National Energy Technology Lab? NETL is the Only Government Owned Government Operated DOE Laboratory MISSION Advancing energy options to fuel our economy, strengthen our security, and improve our environment

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Albany, OR

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Pittsburgh, PA

Morgantown, WV Sugar Land, TX

West Virginia

NETL Researchers Work Closely with Program Staff in Support of the Mission.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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).

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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

200

250

300

Tension, MPa

50

100

150

200

250

300

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

Beg Set

End Set

0.0 0

50

100

150

200

250

Tension, MPa

300

0

50

100

150

200

250

300

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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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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