Publications

While modeling a generic pulse transformer, we became interested in the possibility of electric sparks between winding layers in a solid encapsulant. We significantly modified a previously developed ALEGRA MHD model of a generic spark in lexan. The cumulative modifications are significant enough to report here. Possibly the most significant modification was a change in how the simulated spark is initiated from a thin initial channel. The change was from imposing an initial hot temperature to imposing a conductivity floor. The reasons and comparisons of results are included. The second significant change was to replace a fixed current rise rate with an external circuit model. We built a model specifically mimicking the distributed inductance and stray capacitance between the coil turns closest to the modeled spark. Excursions from nominal values examine the sensitivity of resulting behaviors to extreme capacitance and inductance values.

ALEGRA is a multiphysics finite-element shock hydrodynamics code, under development at Sandia National Laboratories since 1990. Fully coupled multiphysics capabilities include transient magnetics, magnetohydrodynamics, electromechanics, and radiation transport. Importantly, ALEGRA is used to study hypervelocity impact, pulsed power devices, and radiation effects. The breadth of physics represented in ALEGRA is outlined here, along with simulated results for a selected hypervelocity impact experiment.

This is an extension of work described by Rodriguez et al. (2021). It continues analyses of a generic transformer design by Wes Greenwood. In this report, we summarize that work and add comparable results using the ANSYS Maxwell software (henceforward, “ANSYS”), and with COMSOL . We found the ANSYS and COMSOL calculations of inductance agreed well with previous results for simplified coils in air, and with a ferromagnetic core. We then describe the ANSYS and COMSOL approach and show results for a full transformer model based on magnetic field analyses. Finally, we present electrostatic analyses of E field enhancement, once again resolving individual wires. The purpose is to assess the electrostatic fields in order to locate where electric breakdown is likely to originate. We found the maximum enhancement between the secondary and either the primary or the tertiary at the end of the windings with a large potential difference.

Abstract not provided.

We report progress on a task to model transformers in ALEGRA using the “Transient Magnetics” option. We specifically evaluate limits of the approach resolving individual coil wires. There are practical limits to the number of turns in a coil that can be numerically modeled, but calculated inductance can be scaled to the correct number of turns in a simple way. Our testing essentially confirmed this “turns scaling” hypothesis. We developed a conceptual transformer design, representative of practical designs of interest, and that focused our analysis. That design includes three coils wrapped around a rectangular ferromagnetic core. The secondary and tertiary coils have multiple layers. The tertiary has three layers of 13 turns each; the secondary has five layers of 44 turns; the primary has one layer of 20 turns. We validated the turns scaling of inductance for simple (one-layer) coils in air (no core) by comparison to available independent calculations for simple rectangular coils. These comparisons quantified the errors versus reduced number of turns modeled. For more than 3 turns, the errors are <5%. The magnetic field solver failed to converge (within 5000 iterations) for >10 turns. Including the core introduced some complications. It was necessary to capture the core surfaces in thin grid sheaths to minimize errors in computed magnetic energy. We do not yet have quantitative benchmarks with which to compare, but calculated results are qualitatively reasonable.

A verification study is conducted for the ALEGRA software, using the problem of an electrified medium with a spherical inclusion, paying special attention to resistive heating. We do so by extending an existing analytic solution for this problem to include both conducting and insulating inclusions, and we examine the effects of mesh resolution and mesh topology, considering both body-fitted and rectangular meshes containing mixed cells. We present observed rates of convergence with respect to mesh refinement for four electromagnetic quantities: electric potential, electric field, current density and Joule power.

Abstract not provided.