A Novel Air-Cooled Thermal Management Approach towards High-Power Lithium-Ion Capacitor Module for Electric Vehicles

This work presents an active thermal management system (TMS) for building a safer module of lithium-ion capacitor (LiC) technology, in which 10 LiCs are connected in series. The proposed TMS is a forced air-cooled TMS (ACTMS) that uses four axial DC 12 V fans: two fans are responsible for blowing the air from the environment into the container while two other fans suck the air from the container to the environment. An experimental investigation is conducted to study the thermal behavior of the module, and numerical simulations are carried out to be validated against the experiments. The main aim of the model development is the optimization of the proposed design. Therefore, the ACTMS has been optimized by investigating the impact of inlet air velocity, inlet and outlet positions, module rotation by 90° towards the airflow direction, gap spacing between neighboring cells, and uneven gap spacing between neighboring cells. The 3D thermal model is accurate, so the validation error between the simulation and experimental results is less than 1%. It is proven that the ACTMS is an excellent solution to keep the temperature of the LiC module in the desired range by air inlet velocity of 3 m/s when all the fans are blowing the air from both sides, the outlet is designed on top of the module, the module is rotated, and uneven gap space between neighboring cells is set to 2 mm for the first distance between the cells (d1) and 3 mm for the second distance (d2).

Wear of 17-4 PH Stainless Steel Patterned Surfaces Fabricated Using Selective Laser Melting

The recent developments in additive manufacturing (AM) are providing unprecedented opportunities in various fields, including the fabrication of advanced materials for tribological applications. The present work describes the results of an exploratory study focused on the analysis of 17-4 PH steel surfaces obtained using selective laser melting (SLM). In particular, the study includes the analysis of baseline (as-produced) and textured steel surfaces. Surface texturing comprises hexagonal prism structures (with or without dimples) arranged in a honeycomb pattern with 50 µm or 100 µm gap spacing. Starting from the minimum printing size enabled by the 3D printing platform, various textures are prepared by scaling up the characteristic dimensions of the prisms up to 500%. The obtained surface patterns are characterized (qualitatively and quantitatively) using a non-contact computerized numerical control (CNC) measuring system. The coefficient of friction (COF) was investigated using a Ball-on-Disk configuration using bearing steel balls as counterparts. For a fixed sliding speed, different contact loads and sliding radii were considered, while the tests were carried out in either dry or lubricant-impregnated conditions. The results of wear tests in both dry and lubricated conditions indicated that the baseline samples are provided with lower COF compared to the textured ones. For the latter, neither the gap spacing nor the presence of dimples led to significant variations in the COF. However, in lubricated conditions, the values of the COF for baseline and textured surfaces were closer and much smaller. In particular, the results provide clear indications regarding reducing the gap between prisms, which had a beneficial effect on the COF in lubricated conditions. Similarly, sensitivity to dimples was quite remarkable, with a reduction in the COF of about 30% when the larger gap spacing between the prisms was used.

Water droplet can mitigate dust from hydrophobized micro-post array surfaces

Water droplet rolling motion over the hydrophobized and optically transparent micro-post array surfaces is examined towards dust removal pertinent to self-cleaning applications. Micro-post arrays are replicated over the optically transparent polydimethylsiloxane (PDMS) surfaces. The influence of micro-post array spacing on droplet rolling dynamics is explored for clean and dusty surfaces. The droplet motions over clean and dusty micro-post array surfaces are monitored and quantified. Flow inside the rolling droplet is simulated adopting the experimental conditions. Findings reveal that micro-post gap spacing significantly influences droplet velocity on clean and dusty hydrophobized surfaces. Air trapped within the micro-post gaps acts like a cushion reducing the three-phase contact line and interfacial contact area of the rolling droplet. This gives rise to increased droplet velocity over the micro-post array surface. Droplet kinetic energy dissipation remains large for plain and micro-post arrays with small gap spacings. A Rolling droplet can pick up dust particles from micro-post array gaps; however, few dust residues are observed for large gap spacings. Nevertheless, dust residues are small in quantity over hydrophobized micro-post array surfaces.

GaN-Based PCSS with High Breakdown Fields

The suitability of GaN PCSSs (photoconductive semiconductor switches) as high voltage switches (>50 kV) was studied using a variety of commercially available semi-insulating GaN wafers as the base material. Analysis revealed that the wafers’ physical properties were noticeably diverse, mainly depending on the producer. High Voltage PCSSs were fabricated in both vertical and lateral geometry with various contacts, ohmic (Ti/Al/Ni/Au or Ni/Au), with and without a conductive n-GaN or p-type layer grown by metal-organic chemical vapor deposition. Inductively coupled plasma (ICP) reactive ion etching (RIE) was used to form a mesa structure to reduce field enhancements allowing for a higher field to be applied before electrical breakdown. The length of the active region was also varied from a 3 mm gap spacing to a 600 µm gap spacing. The shorter gap spacing supports higher electric fields since the number of macro defects within the device’s active region is reduced. Such defects are common in hydride vapor phase epitaxy grown samples and are likely one of the chief causes for electrical breakdown at field levels below the bulk breakdown field of GaN. Finally, the switching behavior of PCSS devices was tested using a pulsed, high voltage testbed and triggered by an Nd:YAG laser. The best GaN PCSS fabricated using a 600 µm gap spacing, and a mesa structure demonstrated a breakdown field strength as high as ~260 kV/cm.

Passive Thermography Measurement of Damage Depth During Composites Load Testing

Passive thermography is commonly used for composites load testing to detect damage formation as a function of the applied load. The advantages of passive thermography are real time implementation, large area coverage, and noncontact measurement. Passive thermography is able to detect the damage location and size, however, damage depth has been a challenge for quasistatic loading. Recent work has shown that damage formation during loading produces heating that is composed of two heat generation components. The first component is an instantaneous thermal response due to an irreversible thermoelastic strain release due to rapid damage formation. The second component observed is mechanical heating, at the interface of failure, due to fracture damage that produces a transient rise in surface temperature as a function of damage depth. The first component defines the thermal start time for the transient response. A one-dimensional thermal model, that is independent of delamination damage gap spacing, is presented and fitted to the data pixel by pixel, to produce imagery of the damage depth. The percent difference between thermal results, as compared to the ultrasonic measurements of damage length and width, was on average 15%. The percent difference between the thermal results, as compared to the X-ray CT measurements for damage depth was on average 7%. This same processing technique was applied for detection of damage depth during cyclic loading as well.

Nanoelectromechanical modulation of a strongly-coupled plasmonic dimer

The ability of two nearly-touching plasmonic nanoparticles to squeeze light into a nanometer gap has provided a myriad of fundamental insights into light–matter interaction. In this work, we construct a nanoelectromechanical system (NEMS) that capitalizes on the unique, singular behavior that arises at sub-nanometer particle-spacings to create an electro-optical modulator. Using in situ electron energy loss spectroscopy in a transmission electron microscope, we map the spectral and spatial changes in the plasmonic modes as they hybridize and evolve from a weak to a strong coupling regime. In the strongly-coupled regime, we observe a very large mechanical tunability (~250 meV/nm) of the bonding-dipole plasmon resonance of the dimer at ~1 nm gap spacing, right before detrimental quantum effects set in. We leverage our findings to realize a prototype NEMS light-intensity modulator operating at ~10 MHz and with a power consumption of only 4 fJ/bit.

Dealing with the Size Effect in Insulating Liquids. A Volume Effect, an Area Effect or even a Particle Effect?

Insulating liquids play an important role as insulating media in various high voltage applications and infrastructure installations. The dielectric strength of an insulating liquid depends on the experimental conditions (in case of laboratory testing) and/or the service conditions (in case of apparatuses in service). One of the main factors affecting the dielectric strength of insulating liquids is the so-called size effect, i.e. the effect of the size of the electrodes, of the size of the liquid volume under stress and of the gap spacing between the electrodes. All the aforementioned parameters are investigated in the context of the present short review.