DURIP Scaled Additive Manufacturing and Loss Characterization for Research in Ultra-High Frequency Soft Magnet Technology for High Power Applications
Abstract
Recent emergence of switching devices based on wide-bandgap (WBG) semiconductor materials such as SiC and GaN have enabled design of power electronics-based converters with an unprecedented combination of switching frequency, voltage level, and power handling capability. As power electronics engineers have learned to fully leverage capabilities of new switching devices in context of advancedconverter designs, it has become increasingly clear that the passives and in particular, the magnetics, will limit ultimate performance in terms of efficiency, size, and weight. Further advances beyond the WBG based power electronics converters are anticipated in the future as the semiconductor community increasingly looks towards next generation of Ultra-Wide Bandgap (UWBG) semiconductor materials such as Ga2O3 and diamond. Due to frequency ranges anticipated (i.e. 50kHz - MHz) at medium voltage and medium to high power levels (kW to MW-scale) through exploiting unique properties of UWBG semiconductors, successfully realizing the full potential of UWBG based power electronics converters will require new classes of magnetic materials and manufacturing approaches. Numerous technical challenges must be overcome to successfully realize new and optimized magnetic materials for such extreme operational envelopes, and so it is imperative that research efforts for next generation magnetics technologies be carried out in parallel to support future emergence of UWBG power electronics.The current proposal seeks to address needs for advanced magnetic materials and manufacturing methods for emerging UWBG devices through establishment of new manufacturing facilities based upon additive manufacturing that canbe exploited for the design and fabrication of inductors and transformers which operate at unprecedented combinations of electricalswitching frequencies, voltages, and power levels. The facility will be capable of fabrication and performance testing of novel soft magnetic materialand manufacturing approaches for emerging high-power applications within power electronics conversion and conditioning systems of critical importance for next generation Navy and other DOD mobile power applications. More specifically, new binder jet processing additive manufacturing equipment as well as compaction and thermal processing facilities will enable production ofinductor and transformer cores based upon existing commercial as well as novel developed ferrite- and other powder-based soft magnetic material feedstock at a size and scale that can be utilized in practical power electronics converter applications in support of next generation Navy power electronics building block (PEBB) technologies. Advanced loss and performance measurement instrumentation will also be established including MHz-range capable power analyzers and high-speed oscilloscopes equipped with state-of-art voltage and current probes for characterization of material and component properties and performance. The facilities in question will beestablished within the Advanced Magnetics for Power and Energy Development (AMPED) Consortium shared laboratory facility at the Energy Innovation Center (EIC) of the University of Pittsburgh (Pitt), to create a wealth of new opportunities to enhance existing DOD supported research and establish new hands-on educational experiences for both undergraduate and graduate students in electric powerconversion technologies. These new facilities will ensure a foundation of fundamental and applied research in the important, emerging area of advanced magnetic materials and component designs for UWBG semiconductor power electronics applications, as well as engage and train a new generation of materials scientists and electric engineers to prepare the workforce of the future.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Apr 11, 2024
- Source ID
- N000142412235
Entities
People
- Paul R. Ohodnicki
Organizations
- Office of Naval Research
- United States Navy
- University of Pittsburgh