Publications

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Novel multilayered FeSiCrB-Fe x N (x = 2-4) metallic glass composites were fabricated using spark plasma sintering of FeSiCrB amorphous ribbons (Metglas 2605SA3 alloy) and Fe x N (x = 2-4) powder. Crystalline Fe x N can serve as a high magnetic moment, high electrical resistance binder, and lamination material in the consolidation of amorphous and nanocrystalline ribbons, mitigating eddy currents while boosting magnetic performance and stacking factor in both wound and stacked soft magnetic cores. Stacking factors of nearly 100% can be achieved in an amorphous ribbon/iron nitride composite. FeSiCrB-Fe x N multilayered metallic glass composites prepared by spark plasma sintering have the potential to serve as a next-generation soft magnetic material in power electronics and electrical machines.

The size dependence of the dielectric constants of barium titanate or other ferroelectric particles can be explored by embedding particles into an epoxy matrix whose dielectric constant can be measured directly. However, to extract the particle dielectric constant requires a model of the composite medium. We compare a finite element model for various volume fractions and particle arrangements to several effective medium approximations, which do not consider particle arrangement explicitly. For a fixed number of particles, the composite dielectric constant increases with the degree of agglomeration, and we relate this increase to the number of regions of enhanced electric field along the applied field between particles in an agglomerate. Additionally, even for dispersed particles, we find that the composite method of assessing the particle dielectric constant may not be effective if the particle dielectric constant is too high compared to the background medium dielectric constant.

Soft magnetic materials are key to the efficient operation of the next generation of power electronics and electrical machines (motors and generators). Many new materials have been introduced since Michael Faraday's discovery of magnetic induction, when iron was the only option. However, as wide bandgap semiconductor devices become more common in both power electronics and motor controllers, there is an urgent need to further improve soft magnetic materials.These improvements will be necessary to realize the full potential in efficiency, size, weight, and power of high-frequency power electronics and high-rotational speed electrical machines. Here we provide an introduction to the field of soft magnetic materials and their implementation in power electronics and electrical machines. Additionally, we review the most promising choices available today and describe emerging approaches to create even better soft magnetic materials.

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than $\$6$/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of $\$2.7$/kW. New materials such as widebandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective cooptimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

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Barium titanate (BTO) nanoparticles (sizes 10-500 nm) exhibit a displacement of the Ti atom from the center of the perovskite unit cell as inferred from synchrotron x-ray diffraction patterns (XRD) analyzed using atomic pair distribution functions (PDFs). Fits to PDFs acquired at temperatures of 20 °C-220 °C indicate that these Ti displacements (∼0.1 Å) are comparable to or even greater than those in the bulk material. Moreover, these displacements persist at temperatures well above 120 °C, where the tetragonal-to-pseudocubic phase transition occurs in the bulk. Tetragonal Raman spectral lines were observed for all sizes of these BTO nanoparticles and confirm a distorted unit cell up to 120 °C. Above 120 °C, the small BTO nanoparticles (10, 50, 100 nm) continue to display tetragonal Raman lines, though with slowly decreasing amplitudes as the temperature rises. In contrast, the tetragonal Raman lines of large BTO nanoparticles (300, 400, 500 nm) disappear abruptly above 120 °C, suggestive of bulk material. Indeed, fits to large-particle x-ray PDFs over the range 20-60 Å reveal a sharp, long-range structural change toward a cubic lattice at 120 °C, again consistent with bulk material. This sharp, long-range structural change is absent in the small particles. In fact, laboratory XRD Bragg peak profiles for the small BTO particles appear to be singlets at 20 °C, indicating that significant long-range cubic order already exists at room temperature. As temperature rises, this long-range cubic order is gradually reinforced, as inferred from long-range fits of the small particle PDFs. By combining information from x-ray PDFs, Raman spectra, and Bragg peak profiles, we conclude that small BTO nanoparticles exhibit both short-range (unit-cell) distortion and long-range (mesoscale) cubic order from 20 °C to 220 °C, while the large nanoparticles behave as bulk material, differing from small particles only by exhibiting long-range tetragonal order below 120 °C and a mesoscale structural phase change at 120 °C.

Significant reductions recently seen in the size of wide-bandgap power electronics have not been accompanied by a relative decrease in the size of the corresponding magnetic components. To achieve this, a new generation of materials with high magnetic saturation and permeability are needed. Here, we develop gram-scale syntheses of superparamagnetic Fe/FexOy core-shell nanoparticles and incorporate them as the magnetic component in a strongly magnetic nanocomposite. Nanocomposites are typically formed by the organization of nanoparticles within a polymeric matrix. However, this approach can lead to high organic fractions and phase separation; reducing the performance of the resulting material. Here, we form aminated nanoparticles that are then cross-linked using epoxy chemistry. The result is a magnetic nanoparticle component that is covalently linked and well separated. By using this 'matrix-free' approach, we can substantially increase the magnetic nanoparticle fraction, while still maintaining good separation, leading to a superparamagnetic nanocomposite with strong magnetic properties.

This article focuses on the finite element modeling of toroidal microinductors, employing first-of-its-kind nanocomposite magnetic core material and superparamagnetic iron nanoparticles covalently cross-linked in an epoxy network. Energy loss mechanisms in existing inductor core materials are covered as well as discussions on how this novel core material eliminates them providing a path toward realizing these low form factor devices. Designs for both a 2 μH output and a 500 nH input microinductor are created via the model for a high-performance buck converter. Both modeled inductors have 50 wire turns, less than 1 cm3 form factors, less than 1 Ω AC resistance, and quality factors, Q's, of 27 at 1 MHz. In addition, the output microinductor is calculated to have an average output power of 7 W and a power density of 3.9 kW/in3 by modeling with the 1st generation iron nanocomposite core material.

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