Innovative Magnetic Material Solutions for Navy High-Frequency Power Systems
Abstract
Approved for Public ReleaseThe U.S. Navy has invested heavily over the last decades in more #electrified# platforms such as the U.S.S. Zumwalt; F35 Lightning II; active denial and EW platforms; Marine EVs, UAVs, UGVs, and UUVs; among others. Present and future shipboard power systems, such as the Navy#s Power Electronic Power Distribution System featuring the Hybrid Energy Storage Magazine require high-performance magnetic materials that operate at frequencies from 0.5 < f < 5 MHz. Other needs are those of pulsed power directed energy systems that require magnetic materials to operate at frequencies up to and beyond 250 MHz; in all cases, commercial off-the-shelf products fall far short of providing effective solutions for the Navy#s power conversion, conditioning, and storage needs. To address these Navy needs, the proposed research delivers innovative solutions in the design, development, and manufacturing of a new generation of high-performance magnetic composites through two Materials Focus Areas (MFAs) and one Additive Manufacturing Focus Area (AMFA). These focus areas are guided and supported by simulation, modeling, and testing that will provide critical Navy application-driven assessment for novel materials and components developed throughout the program. Improved material and component modeling will be developed, thorough measurements of performance parameters will be performed, and prototype components will be designed and developed. MFA-I objectives are to establish optimal compositions and/or composites that function over the frequency range 0.5 < f < 5 MHz. and to develop processing protocols that ensure cost-effective and large-scale production for shipboard power needs. Research will leverage high flux densities attainable through high-permeable metallic soft magnetic alloys with reduced eddy currentlosses achieved through high resistivity ferrite-based materials in the form of novel metal/ferrite nanocomposite systems achieved through scalable manufacturing pathways. Research will further develop and advance the concept of grain boundary engineered ferritescomprised of ferrite/ferrite nanocomposites. MFA-II objectives are to demonstrate and validate optimal compositions and/or composites that function up to and beyond 250 MHz to address Navy need for efficient high power pulse generators (HPPGs) for active denial and EW and counter EW applications, among others. Ferrite-ferrite and ferrite-metal composites will be explored and Extended Medium Approximations (EMA) modeling will be employed to guide design and aid in processing of thermally stable composite structures. Parameters to be refined and optimized include component composition, particle size, morphology, mixing ratios, and dispersion and distribution. The objective of AMFA is to develop scalable additive manufacturing pathways for high quality, cost-effective, volumetric production of inductor components valued for power electronic systems. Specifically, binder jet 3D printing will be the principal approach to optimize feedstock powder, print green products, while minimizing shrinkage and eliminating cracks. Post-processing will leadto high-density, high-quality, cost-effective inductor cores ready for extensive performance testing. This processing path will naturally lead to a safe and secure supply chain, which is an increasingly valuable asset.In addition to addressing the power needs of critical Navy platforms that have been stymied in development by the lack of suitable commercially available materials, dual-use opportunities of MHz power inductors are plentiful, including electric vehicles, green energy, power grids, data centers, and all manner of propulsion ranging from auto, freight, air, water, and space. HPPGs find unique opportunities in advances life sciences emerging cancer remediation therapies.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Nov 08, 2024
- Source ID
- N000142412513
Entities
People
- Vincent G. Harris
Organizations
- Northeastern University
- Office of Naval Research
- United States Navy