Update on UFTO Operation Update

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See earlier note attached below. Thanks to the many of you who responded.

We are making progress.

OAK RIDGE — tentatively scheduled for sometime Apr 1-3.
Need to know — WILL YOU COME??

NIST — looking for a date in May

ARGONNE — we’d hoped to go to ANL in March, however they’re gearing up for an initiative to approach utilities, and will be better prepared for us if we wait until June. I’ll keep you posted.
(note to Cubs fans–see how things work out?)

Subject: UFTO Operation Update
Date: Wed, 21 Jan 1998 09:41:54 -0800
From: Ed Beardsworth
To: note@ufto.com

————————————————————–
| ** UFTO ** Edward Beardsworth ** Consultant
| 951 Lincoln Ave. tel 650-328-5670
| Palo Alto CA 94301-3041 fax 650-328-5675
| http://www.ufto.com edbeards@ufto.com
————————————————————–

At our June meeting in SF last year, there was a strong consensus behind the idea to revisit some of the Labs that we first went to several years ago. I’ve already gone to Sandia, and am beginning to put the plans in place for other Labs.

A number of you expressed an interest in accompanying me on such trips, so this note is to find out how many of you are likely to come.

The format will depend on how many of you attend, and what your interests will be. I would go ahead for meetings on Day 1, and then be prepared for your arrival that evening. Day 2 would be tours, presentations and meetings for the group. You certainly could expect a good overview of relevant programs at each Lab, and a chance to meet some of the management and key investigators.

I’ve contacted Oak Ridge, Argonne, and NIST, to start the process of finding possible dates. My goal is to accomplish all three visits by the mid July, though we may let one slide to the Fall.

(To review our materials for each of these labs, go to the website/ members only/ “advanced” search, and put the lab name in “Source”…For NIST use “institute”. Also, note new “reports and workshops” section.)

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It’s very important to have good estimates for this. Please REPLY, by cob Tues Jan 27. Thank you.

A. ____ NIST (Wash DC)
____ Oak Ridge (Tenn.)
____ Argonne (Chicago)

_1_ Almost certain we will send someone, schedules permitting
_2_ A distinct possibility
_3_ Almost certainly won’t send anyone

B. Comments or suggestions on:
TIMING? (good, bad dates–preferred days of week, etc.)
AGENDA?
Other comments?

C. ____ UFTO Members Meeting?
When? Where? (Combine with a Lab visit? Another event?)
Comments?

Chemical Treatments Neutralize Asbestos

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Brookhaven National Lab and WR Grace issued a major joint press release last December (attached below) announcing the development of a new commercially available treatment process that changes the chemical makeup of chrysotile asbestos. This is the type of asbestos used in fireproof coatings on structural steel.

The process destroys the asbestos in place, while maintaining its fireproofing properties. An acidic foam is applied, which soaks in and digests the asbestos molecules. The resulting material simply is not asbestos any more.

Contact Len Ciesluk, 410-531-4645, leonard.ciesluk@grace.com

The form of asbestos used for thermal insulation (e.g. pipe wrapping and boilers, etc.) contains a different form of asbestos called amosite. The WR Grace process does not apply to amosite, but work is proceeding rapidly at Brookhaven on other formulations that will deal with both types of asbestos (sometimes a mix is used). Brookhaven is applying for patents, and is looking to DOE for additional funding. They’ve already begun discussions with a few utilities, and would be delighted to talk to UFTO companies about working with them to turn this new chemistry into a commercial process, estimated to require only a few months.

Contact is Leon Petrakis, 516-344-3037, petrakis@bnl.gov
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W.R. Grace – BNL Press Release
ISSUED DECEMBER 10, 1997

–Product Destroys Asbestos While Maintaining Original Materials’ Fire-resistive Capabilities on Columns and Beams–

–Product Should Provide Significant Cost Savings to Building Owners–

The new technique uses a foamy solution sprayed directly onto asbestos-containing fireproofing. The foam chemically digests asbestos fibers, dissolving them into harmless minerals.

When the treatment is done, the fireproofing is no longer a regulated material. The process is the first to chemically destroy asbestos without first removing the fireproofing.

Grace anticipates that building owners will realize significant cost savings from the new product. Current techniques for removing asbestos-containing fireproofing require the construction of air-tight barriers, labor-intensive scraping of the fireproofing, and the installation of new asbestos-free fireproofing. The new product eliminates the need to remove and replace older material and substantially reduces the time needed for the entire process. Moreover, the new process produces essentially no waste and is expected to save building owners the expense of disposing of regulated waste materials.

The new product is expected to be commercially available in early 1998.

Larry Ellberger, chief financial officer and acting chief executive officer of Grace, stated, “This product is an important advance in the science of asbestos abatement. Our scientists embarked on this research several years ago because it was a natural extension of our expertise and because we were committed to helping our customers find a more time-efficient and cost-effective alternative to asbestos removal. We are gratified by the excellent collaboration we have had with the scientists at Brookhaven, whose expertise in chemistry and materials science was a perfect complement to our scientists’ knowledge of the product and its properties. Brookhaven’s involvement was critical to the timely completion of this project. This is a win-win for Grace shareholders, building owners and industry-government cooperation.”

Dr. Leon Petrakis, the senior scientist in charge of the project at Brookhaven, said, “We are delighted to have worked with Grace on this project. We believe our collaboration has led to a turning point in the important but until now rather overlooked science of asbestos abatement. This method could be used in thousands of schools, office buildings, hospitals, and other institutions around the country. We also believe it could lead to the development of a family of innovative materials that chemically digest asbestos-containing materials, with potential applications for addressing asbestos in thermal insulation at the Department of Energy, in other governmental facilities and in the utility industry.”

Extensive Tests Performed

Full-scale tests performed with the new product by Grace and Brookhaven have confirmed that its use would reduce asbestos to less than 1 percent, which is the Environmental Protection Agency’s definition of non-asbestos materials. The asbestos-neutralizing process was first evaluated in Brookhaven’s unique testing laboratory, specially equipped to handle asbestos. It was then tested at a vacant four-story building with existing asbestos-containing fireproofing.

All tests performed to date used Grace’s asbestos fireproofing. Project scientists, who are knowledgeable about the composition of asbestos-containing fireproofing made by others, believe the process should be effective on most of those products as well.

Although most of the efforts thus far have been centered around spray-applied fireproofing, laboratory tests conducted by Grace and Brookhaven have confirmed that the digestion process should also be effective with acoustical plasters.

Grace expects to receive six patents for the new asbestos-neutralizing process. Brookhaven has received one patent relating to the process and is applying for two others.
Brookhaven and Grace also developed a new quantitative analytical method that detects chrysotile asbestos fibers in material containing as little as 0.1 percent of the fibers. Development of the technique utilized the powerful X-rays of Brookhaven’s National Synchrotron Light Source, as well as conventional laboratory instruments.

Scientific Cooperation at Work

The development of the asbestos-neutralizing process began at Grace several years ago. Through mutual participation in the Council for Chemical Research, scientists from Grace and Brookhaven met to discuss ways that Brookhaven could participate in the research.

The partners signed a Cooperative Research and Development Agreement, or CRADA, which provided for joint funding of the multi-million dollar project. The project also received funding from the Department of Energy, which represents cooperation within that agency, including the DOE’s Office of Environmental Management and the Office of Energy Research. Initial funding also came from Brookhaven’s pool of Laboratory Directed Research and Development funds and its Department of Applied Science.

Grace, based in Boca Raton, Florida, is a leading global supplier of flexible packaging and specialty chemicals with annual sales of $3.5 billion. Grace is the world’s leading producer of spray-applied fireproofing–Monokote® MK-6– to protect structural steel against damage from fire. Grace operates in more than 100 countries.

Brookhaven National Laboratory carries out basic and applied research in the physical, biomedical and environmental sciences and in selected energy technologies. Brookhaven is operated by Associated Universities, Inc., a nonprofit research management organization, under contract with the U.S. Department of Energy.
# # #
STATEMENT BY U.S. SECRETARY OF ENERGY FEDERICO PEÑA

Brookhaven Laboratory scientists have helped create an innovative, safe solution to a tough problem that affects people around the country. This is just one example of many achievements at Brookhaven, known for its contributions in medicine, basic research, energy and environmental science. Partnerships between Department of Energy laboratories and private industry consistently reap tangible rewards. In this case, we will make a difference in safely removing asbestos from schools, houses, offices and other buildings.”

Next Meeting DOE Reliability TF

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Next (8th) Meeting DOE/SEAB- Electric System Reliability Task Force
Tuesday, March 10, 1998, 8:30 AM – 4:00 PM.
ANA Hotel, Ballroom I, 2401 M Street, NW, Washington, D.C. 20037

FOR FURTHER INFORMATION CONTACT: Richard C. Burrow, Secretary of Energy Advisory Board (AB-1), U.S. Department of Energy, (202) 586-1709 or (202) 586-6279 (fax).

Background

The electric power industry is in the midst of a complex transition to competition, which will induce many far-reaching changes in the structure of the industry and the institutions which regulate it. This transition raises many reliability issues, as new entities emerge in the power markets and as generation becomes less integrated with transmission.

Purpose of the Task Force The purpose of the Electric System Reliability Task Force is to provide advice and recommendations to the Secretary of Energy Advisory Board regarding the critical institutional, technical, and policy issues that need to be addressed in order to maintain the reliability of the nation’s bulk electric system in the context of a more competitive industry.

Tentative Agenda
Tuesday, March 10, 1998
8:30 – 8:45 AM Opening Remarks & Objectives
— Philip Sharp, ESR Task Force Chairman
8:45 – 10:15 AM Working Session: Discussion of Draft Position Paper
on Technical Issues in Transmission System Reliability
10:15 – 10:30 AM Break
10:30 – 11:45 AM Working Session: Discussion of a Draft Position Paper
on the Role and Shape of the Independent System Operator
11:45 – 12:45 PM Lunch
12:45 – 1:45 PM Working Session: Discussion of a Draft Position Paper
on Ancillary Services and Bulk-Power Reliability
1:45 – 2:45 PM Working Session: Discussion of a Draft Position Paper
on Incentives for Transmission Enhancement
2:45 – 3:30 PM Working Session: Guest Presentation & Discussion of
State and Regional Reliability Issues
— Philip Carver, Oregon Office of Energy
3:30 – 4:00 PM Public Comment Period
4:00 PM Adjourn

This tentative agenda is subject to change. The final agenda will be available at the meeting.

Public Participation: The Chairman of the Task Force is empowered to conduct the meeting in a fashion that will, in the Chairman’s judgment, facilitate the orderly conduct of business. During its meeting in Washington, D.C., the Task Force welcomes public comment. Members of the public will be heard in the order in which they sign up at the beginning of the meeting.

Information on the Electric System Reliability Task Force and the Task Force’s interim report may be found at the Secretary of Energy Advisory Board’s web site, located at http://www.hr.doe.gov/seab.

Sandia Help Implementing Solar

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Sandia to Help Utilities Implement Solar Energy

Sandia has received funding to work with utilities interested in teaming with the solar industry to install solar systems in their territory. The team will provide technical expertise to the utility in selecting technologies and, if warranted, work with industry partners to improve their systems. This may result in partnerships (such as CRADAs) with some utilities and industry members.

Sandia staff are currently lining up utilities to visit for exploratory meetings. For more information (and to be among the first companies to take advantage of this),

Contact:
David Menicucci, 505-844-3077, dfmenic@sandia.gov

For background on Sandia’s renewable programs, their web site is at:
http://www.sandia.gov/Renewable_Energy/renewable.html

The goal is to help energy users consider and properly implement renewable energy technologies, as part of an educational outreach and technology transfer service on behalf of the Department of Energy’s investment in development, commercialization, and deployment of renewable energy technologies. This effort is designed to complement, not compete with, the technical services available through the US industry.

Sandia’s Renewable Energy Team is a cross-technology group of engineers with a primary focus on solar thermal, photovoltaic, wind, geothermal, and biomass systems. They can provide: 1) An on-site assessment of energy needs applicable to renewable energy systems, 2) Help in renewable energy program planning and implementation, 3) Help in deciding whether renewable energy can work in certain applications, 4) Expert advice in choosing renewable energy systems, 5) Calculations about the projected energy and economic performance of a renewable energy system, 6) Advice during design and procurement, construction, operation of the system, and operations monitoring, 7) Analysis, testing, and evaluation of systems, and 8) Training in renewable energy systems.

UFTO Website enhancements

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Have a look at the UFTO Website. There’ve been some changes.

* Updated the Database**, adding material from UFTO Notes thru last week.

* Added new reports for Wright Lab, NASA Ames, Ames Lab and Ontario Hydro

* Added an “orientation” section to the Clients Only page

* Various layout changes

A couple of member companies are getting close on plans to set up a link to the UFTO website on their company’s internal website, and hopefully will be able to deal with the password access in an automatic way. I’ll let you know how it goes.

Remember the standing offer that anyone in your company can be added to the list to receive UFTO Notes.

As always, suggestions are most welcome.

Ed

** I did not include recent UFTO Notes about activities of the DOE SEAB Reliability TF, under the assumption that anyone who cares about that probably knows about it (and TF’s own website) by now. Let me know whether you agree.

Technology Transfer Opportunities – Wright Laboratories

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UFTO

PROPRIETARY

Final Report

Technology Transfer Opportunities in the Federal Laboratories

Wright Laboratories

U.S. Air Force

Dayton OH

February 1998

Prepared for:

Utility Federal Technology Opportunities (UFTO)

By:

Edward Beardsworth

Consultant

This report is part of a series examining technology opportunities at National Laboratories of possible interest to electric utilities

 

Contents:
page
1. Summary
1 Overview & Organization
3. Technologies & Programs

This report is proprietary and confidential. It is for internal use by personnel of companies that are subscribers in the UFTO multi-client program. It is not to be otherwise copied or distributed except as authorized in writing.

Summary

This report details findings about technology and technology transfer opportunities at the Wright Laboratories that might be of strategic interest to electric utilities. It is based on a visit to the lab in June 1997 and subsequent contacts, as part of the UFTO multiclient project.

Background

Noting the tremendous scope of research underway in the research facilities of the U.S. government, and a very strong impetus on the government’s part to foster commercial partnering with industry and applications of the technology it has developed, the UFTO program has been established as a multi-client study of the opportunities thus afforded energy utilities and their many subsidiaries.

Air Force Research Laboratory

In a major reorganization just put into effect in mid 1997, all the Air Force R&D activities were brought together into one single entity called the Air Force Research Laboratory.

From the AFRL website: http://www.afrl.af.mil/

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The mission of the Air Force Research Lab is to lead the discovery, development, and transition of affordable, integrated technologies for our air and space forces — to keep our Air Force "the best in the world." Our mission is executed by our nine technology directorates, located throughout the United States; the Air Force Office of Scientific Research; and our central staff. Our partners include universities and industry, with whom we invest almost 80% of our budget, and our customers include the Air Force major commands, who operate and maintain the full spectrum of Air Force weapon systems. We are a full-spectrum laboratory, responsible for planning and executing the Air Force’s entire science and technology budget: basic research , applied research, and advanced technology development. The work is done at facilities all across the country (Wright-Patt, Kirtland, Brooks, Edwards, Eglin, Tyndall, Bolling, Hanscom, Rome).

The AFRL is made up of more than 6400 government people, which includes over 1500 military and over 4800 civilian personnel. We have about 3500 scientists and engineers, of which over 800 have PhDs.

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Budgets and staffing of research groups and facilities are relatively stable over time, as the Air Force regards its research capability as vital to the conduct of its overall mission, and takes a long view of its future technological needs.

• Technology Transfer

The Air Force, like all of DOD, has a strong commitment to Tech Transfer, and like DOE and other agencies,has a wide latititude of contracting mechansims and ways of working together with private industry and academia. One of the primary motivations for working with the commercial sector is to enhance the capabilities of private industry so as to lower costs to the Air Force of the high-value manufactured items they need.

The AFRL operates Tech Connect, the main point of contact for tech transfer for the entire Air Force. It provides search and contact services and facilitation.

In addition, each operating location (not just labs) have their local point of contact or ORTA (Office for Research and Technology Application).

To contact TECH CONNECT

Call – (937) 656-2530 Toll Free (800) 203-6451 FAX (937) 656-2138

Web site — http://tto.wpafb.af.mil/tto/techconn/index.htm

Wright Labs Overview

Wright Laboratories, located at Wright Patterson Air Force Base, Dayton OH, is oldest and largest of the Air Force research laboratories, with a history stretching back to 1917.

Wright Labs is headquarters for a number of Directorates (e.g. armament, avionics, flight dynamics, etc.).

Propulsion Directorate http://www.pr.wpafb.af.mil/

One of these, the Propulsion Directorate, has the highest relevance for utilities.

The Propulsion Directorate’s work has many potential non-aerospace and commercial uses in:

– Materials and Materials Application
– Measurement and Sensing
– Modeling and Visualization
– Energy and Power

With an annual budget of about $150 Million, and about 300 mostly technical and scientific personnel, its technical divisions are:

Division – Office Symbol (Primary Site/Secondary Site)

– Power Division – AFRL/PRP (WP)
– Propulsion Sciences and Advanced Concepts Division – AFRL/PRS (Edwards/WP)
– Turbine Engine Division – AFRL/PRT (WP)
– Rocket Propulsion Division – AFRL/PRR (Edwards)
– Integration and Operations – AFRL/PRO (WPAFB/Edwards)

Principal Point of Contact: Kristen Schario, 937-255-2131, scharika@wl.wpafb.af.mil

Power Division http://www.pr.wpafb.af.mil/divisions/prp/prp.html

The Power Division plans, formulates, manages and executes research, exploratory and advanced development programs in energy conversion and storage, and power generation, transmission, conversion, and thermal management. This includes electrical, mechanical, thermal, and fluid power for aircraft, missile, terrestrial, and special Air Force applications.

Technologies & Programs

Covered in this report:

Page
• More Electric Aircraft (MEA) 4
Power generation
Power systems and distribution components
Passive components – Capacitors
Power electronics/motor drives
• Ground Power 4
Remote Small Scale (10-120 watts)
Cryogenic Lightweight Deployable (1-4 MW)
• Turbine Compressor Research Facility 8
• Electronics Cooling
• Mechanical Testing of Electrical Machinery
• Silicon Carbide High Power Electronics
• Superconductors, Cryogenic Power Electronics
• Batteries 4
• Lubrication Technology 4

• More Electric Aircraft (MEA)

Contact: Maj. Michael Marciniak, 937-255-6226, marcinma@wl.wpafb.af.mil

The Air Force has a major effort on the "More Electric Aircraft" (MEA), from which many "dual-use" applications arise. As with the more electric ship and tank, the PNGV hybrid/electric vehicle efforts share many common requirements and opportunities.

The goal of MEA is to replace hydraulic and pneumatic systems, which account for more than 1/2 of all downtime and failres of fighter aircraft, with electrical ones. A wide range of technologies are involved, including actuators, electronics cooling, motor/alternators, supercapacitors, batteries, power system controllers, and high power semiconductor devices.

The MEA will require a highly reliable, fault tolerant, autonomously controlled electrical power system to deliver high quality power to the aircraft’s loads. Also, reliable high power density motors and motor drives ranging from a few horsepower to hundreds of horsepower will be required

Military aircraft have numerous subsystems powered by one or more sources of secondary power: hydraulic, pneumatic, electrical and mechanical. Secondary power is typically extracted from the main engines mechanically by a driven shaft and pneumatically by bleeding the compressor. Mechanical power is distributed to a gearbox to drive lubrication pumps, fuel pumps, hydraulic pumps and electrical generators. Pneumatic power typically drives air turbine motors for engine start systems and environmental control systems. Electrical power and hydraulic power are distributed throughout the aircraft for driving subsystems such as flight control actuators, landing gear brakes, utility actuators, avionics, and weapon systems.

Recent and projected advancements in aircraft electrical power system and component technologies have resulted in renewed interest in the MEA. For example, hydraulically driven actuators would be replaced by electric motor driven actuators, gearbox driven fuel and lubrication pumps would be replaced by electric motor driven pumps, and a pneumatically driven compressor for environmental control would be replaced by an electric motor driven compressor. Studies on two different military fighter aircraft have shown that the MEA concept provides significant reliability, maintainability and supportability payoff.

There are four major technical thrusts in the roadmap: (1) power generation, (2) power systems and distribution components, (3) passive components, and (4) power electronics/motor drives

Power Generators — Independent Power Units (IPU)

A High Reliability Generator was developed from a conventional 400 Hz Variable Speed Constant Frequency (VSCF) system to a dual output (270 VDC and 400 Hz) system capable of supporting the near-term MEA.

The Switched Reluctance Starter/Generator program developed the preliminary design for a 375 KW, 270 VDC switched reluctance starter/generator in which the electrical machine is integrated internally with an advanced gas turbine engine.

A smaller 250 KW unit was built and tested to demonstrate the critical technologies. The switched reluctance starter/generator system offers a robust, high temperature, fault tolerant solution for the environmental demands of the turbine engine and the performance demands for the MEA.

Feasibility is based upon recent advancements in power electronic component technologies, high temperature wire insulation, and high temperature, high strength magnetic materials. The power electronic inverter is essential to the system since it provides the means to excite and process power to and from the unit. An Electro-Magnetic Interference (EMI) filter will reduce unwanted frequency components.

These systems are directly applicable to ground applications. In fact, Allied Signal is the contractor, which no doubt contributes to their civilian microturbine program.

In another development, an internally integrated 375 KW Starter/Generator for large aircraft enginees will include the critical step of eliminating the engine gearbox and aircraft mounted accessory drive. Integration into the gas turbine engine is enabled by high strength, high

temperature permanent magnet materials (cobalt-iron) and reliable high temperature wire insulation.

Power Systems and Distribution Components

The MEA will need a highly reliable, fault tolerant, autonomously controlled electrical power system to deliver high quality power from the sources to the load.

There are several challenges in designing an electrical power system for a MEA. Total onboard power requirements will be much greater, ranging as high as 1-10 MW per aircraft. It adds substantial amount of high power dynamic motor loads which could impact power quality. Most of these loads will have a low input impedance "capacitive" EMI filter which could present an in-rush current problem. Some MEA loads such as flight control actuators could provide regenerative energy back to the power distribution system.

Most important, these loads are flight critical, and loss of power to these loads could result in the loss of the aircraft. Thus, the performance and integrity of the power distribution system becomes a critical network which links sources to loads.

Presently, the Air Force has two programs for power systems and distribution components for the MEA.

– Power Management and Distribution for More Electric Aircraft (MADMEL) program
– Remote Terminal utilizing 270 VDC Solid State Power Controller program.

Future programs include development of: (a) high current (>50 ampere) intelligent power controllers and contactors that provide control, protection, and status feedback. (b) smart, overcurrent, differential current, and ground fault protection systems, (c) arc detection circuits to trigger protection devices in the event of an arc. (d) highly reliable and rugged connectors and interconnect components.

Passive Components – Capacitors

— Contact: Sandra Fries-Carr, 937-255-6016, carrsj@wl.wpafb.af.mil

State-of-the-art aircraft capacitors are considered to be the weakest link in power electronic systems. They are also large, heavy and lossy. This is a real concern for the MEA since 100s to 1000s of capacitors will be required for filtering and energy storage. The Air Force is pursuing several organic and inorganic capacitor technologies under contract that promise improvements in reliability, size, weight, and electrical and thermal performance.

Foster-Miller Corp. was awarded an SBIR contract to examine the application of PBZT polymer film for capacitors. This film demonstrated dielectric strengths as high as 100,000 Volts/Mil and low dissipation factor at high temperatures (up to 300*C). A follow-on SBIR contract to Foster-Miller further developed the PBZT film to make highly reliable, high energy density capacitors with operating temperatures to 300*C.

Westinghouse Science and Technology Center was under contract to develop and demonstrate high temperature (>200*C) AC and DC filter capacitors using a FPE polymer film from 3M Corporation. The capacitors were tested with a Variable Speed Constant Frequency (VSCF) generator system and demonstrated over 2000 hours of trouble free operation at 225*C.

Olean Advanced Products, Division of AVX Corporation is under contract to develop multilayer ceramic capacitors with increased operating temperature (up to 300*C) and reduced dissipation factor over a wide frequency and temperature range. Ceramic capacitors offer tremendous volumetric density compared to other capacitor technologies.

Wright Labs, in-house, is using low temperature RF sputtering to make very thin film ceramics (600 angstroms) which can be put directly on a circuit board.

Ultra high energy density pseudo capacitors have been developed, demonstrating energy densities over 11 Joules/gram and possibly as high as 30 J/g. An inexpensive device about the size of a quarter, weighing 6 grams, is rated at 5 farads at 5 volts. These are use in burst power and other aircraft and civilian applications, and can be stacked to the 1 KV level.

Diamond Thin Film Capacitors

The Air Force is conducting an in-house research program to investigate the possibility of using diamond-like carbon and polycrystalline diamond films as dielectric materials for capacitors. Diamond has the highest thermal conductivity of any material known and a very high dielectric strength, electrical resistivity and operating temperature capability. Wright Labs has made thin films using microwave plasma-enhanced chemical vapor deposition that have very stable performance over a wide temperature range. Capacitors continue to work well at 600 deg C, with a power density of 7 Joule/gram.

The Air Force has recently awarded several contracts to investigate other promising dielectric materials and construction techniques for capacitors. This includes silicon carbide, barium titanate, and multi-layer diamond capacitors.

Power Electronics and Motor Drives

— Contact: Clarence Severt, 937-255-6235

Advancements in power semiconductor devices, capacitors, and integrated circuits for control has enabled high density, reliable power electronic and motor drive systems that are essential for the MEA. These include generators, battery chargers, DC to AC inverters, and DC to DC converters, and motor drives, which provide the interface between the electrical power system and the motor.

To date, the Air Force has focused on MOS Controlled Thyristor (MCT) switching device and the MCT driver. Future work will center on Application Specific Integrated Circuit (ASIC) technology for motor drive controls and the development of advanced drives for induction, permanent magnet, and switched reluctance motors.

In September 1986, the Air Force awarded a contract to the General Electric Corporate Research and Development Center to develop a high power MCT device. At that time, GE had only demonstrated a small MCT device capable of a few Amps and a 200 Volts. The objective of this contract was to develop and demonstrate a high power device (with several orders of magnitude increase in power handling capability) that would be applicable to aircraft power conditioning. The goal was to develop a 150 Ampere 900 Volt device capable of high speed operation (200 nanosecond turn-on and 1 microsecond turn-off capability), low forward voltage drop (1 Volt) and high temperature capability (>200*C junction temperature).

Later in the contract, an integrated circuit driver chip was developed that provides an interface between logic control signals and the gate of the MCT. This program was successful in meeting its goals, and several hundred first generation MCT devices and driver circuits were produced, with significant performance improvements as well as size and weight reductions when compared to bipolar junction transistor technology available at that time.

A second contract was awarded to GE to make the MCT an acceptable and preferred device for military weapon systems such as the MEA. This contract is focused on advanced hermetic packaging, radiation hardening, and symmetrical voltage blocking for AC applications. Also improvements to the MCT are being investigated which offer improvements in peak current turn-off capability and current density.

———————————————————-

• Ground Power

Remote Small Scale (10-120 watts)
— Contact: Tom Lamp, 937-255-6235, xxxx@wl.wpafb.af.mil

The Air Force has over 80 remote sites in Alaska that need ultra high reliability power sources in the 10-30 watt range, for sensor systems, to 120 watts. Most are equipped with thermoelectric generators (TEG) that operate on propane, with some photovoltaic. The transportation costs run to $30-40 per pound of fuel, so the low efficiency of TEG, typically about 5%, is obviously a concern. Requirements are unattended operation, low health and safety risk to local population and Air Force personnel, and low environmental risk. Installation must be quick, by heliocopter drop-in. Weather conditions are very extreme.

But for the social outcry that would result, RTG’s are the obvious best choice (radionuclear thermal generators–as used on space missions). Other mature technologies include batteries, fuel cells, wind and engines, none of which meet the objectives.

Other choices are Stirling, Thermionic, Thermophotovoltaic, and AMTEC, all of which are small scale heat-to-electricity conversion devices with higher efficiency than TEG.

Stirling is under development by NASA for slightly larger systems (350 watts), and DARPA is funding some work on TPV and AMTEC ( a 500 watt compact system for the Army).

For the Alaska sites, the conclusions are that AMTEC and Stirling are the best candidates. Work is underway to develop prototype systems, building on the work done for space power systems. Commercial applications could include gas metering, navigation stations, weather monitors, and cathodic protection.

Cryogenic Lightweight Deployable (1-4 MW)
— Contact Jerry Beam, 937-255-6226

The Air Force needs lightweight deployable power plants to support, as one example, ground based radar (GBR) systems. Conventional technology and it’s supporting infrastructure is larger and heavier than wanted, and one of the Air Force’s key goal is to reduce the "logistics tail" whenever possible. A study showed that the conventional GBR plant with 5 semi-trailers and 140 cubic meters in volume, could be reduced to 2 trailers by the use of a superconducting cryogenic power generator. Since the radars already need cryogenic support, this is not an additional requirement, and the size and efficiency gains are significant. A prototype system will be tested in 2000, and could be in the field by 2005.

• Turbine Compressor Research Facility (CRF)
— Contact: Mark Reitz, 937-255-6802

The CRF is a major facility for conducting tests and evaluations of full scale multi stage and single shaft fans and compressors for gas turbine engines. Extending over four buildings, it is capable of 30,000 hp at speeds to 16,000 rpm, and 15,000 hp from 16 to 30,000 rpm. It can create steady-state and transient phenomena on full size test articles under conditions that are similar to those of actual operation. It has been used for many advanced turbine development programs to evaluate fans and core compressors.

Solar Turbines, Inc. is developing gas fired turbine engines for cogeneration and industrial drive applications in industry, under a CRADA with DOE’s advanced turbine program. The compressor for this engine is now under test at the CRF to identify any possible design deficiencies. This is the first major commercial use of the CRF.

• Electronics Cooling
— Contact John Leland, 937-255-2922

Cooling of power electronics is particularly important as systems become more compact and powerful. Anticipating cooling requirements up to 600 W/sq cm, a number of initiatives at the Lab include:

— testing performance of heat pipes in aircraft-type environments, e.g. under acceleration and vibration. Contact Kirk Yerkes, 937-255-6241
— integration of direct spray cooling into a 270 V 400 A single phase inverter, leading to a reduction in size of 10X. Direct immersion, jet impingement and flow boiling are also receiving attention. Contact Brian Donovan, 937-255-6241
— Venturi flow cooling is another technique under consideration

• Mechanical Testing of Electrical Machinery
— Contact Tim Young
— Characterization of soft magnetic materials at higher speeds and temperatures encountered in IPU’s
— Windage in generators can become a significant power loss (as much as 30-40%) at high RPM due to viscous air losses.

• Silicon Carbide High Power Electronics
— Contact: Clarence Severt, 937-255-6235

Compared with silicon, Silicon Carbide semiconductors have 3 times the band gap, and a operating temperature range reaching 4-600 deg. C, compared with 125 deg. C for silicon. It also has higher breakdown strength, which can mean thinner devices. Also, increased circuit efficiencies can reduce heat loads as much as 5X.

The main obstacle to using SiC in power electronics is the difficulty in making it without defects. "Micropipes" form too easily as the material is built up by vapor deposition.

The Air Force program has focused on development of high quality semiconductor grade material, improving on both wafer size and defect rates, for an aggressive development effort for power electronic devices. They have set a goal to demonstrate a 100-amp 600-V 572 deg F SiC switch by the year 2002.

For the power industry, discussions were well along with EPRI last year on possible cofunding of several device programs, but EPRI backed out. No new initiatives have come forward since.

——press release by CREE Research, one of the key developers in this program——–

Cree Unveils New Product Offerings for Silicon Carbide Wafers 40% Reduction in Micropipe Densities on Silicon Carbide Material

(Durham, NC May 27, 1997) Cree Research Inc. [NASDAQ: CREE] today announced that it has made tremendous progress in its efforts to reduce micropipes within its silicon carbide (SiC) material. Cree will now offer its 4HN type SiC wafers with reduced micropipe densities (MPD) and graded to three categories. The low grade will have a maximum of 30 micropipes/cm2, which represents a reduction in MPD of 40%. A new select grade will be added, which will have a range of 31 to 100 micropipes/cm2. In addition to Cree’s low and select grades, the standard grade will have a range of 101 to 200 micropipes/cm2. This represents a reduction in MPD of 50%.

Christer Ovren, Director of Silicon Carbide Device Development at Asea Brown Bovari (ABB), commented that "Cree continues to lead the world in making lower micropipe substrates available for the research and development of next generation devices. This latest advance is another step forward in maturing the manufacturing process for silicon carbide technology." ABB has purchased SiC wafers from Cree for a number of years.

These reduced micropipe densities are a result of Cree’s continuous commercialization of its SiC material technology. Cree expects this technology breakthrough to enable SiC material for more applications and improve device performance of existing applications. North Carolina based Cree Research, Inc. is the world leader in the development of silicon carbide-based semiconductors which have potential advantages in certain optoelectronic, RF and microwave, power, and high temperature applications. Cree owns outright or licenses exclusively 40 patents related to its process and device technology.

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• Superconductors, Cryogenic Power Electronics
— Contact: Charles Oberly, 937-255-4814

As noted above, cryogenic systems can have dramatically improved efficiency, size reduction, and performance as compared with standard counterparts. Power conversion efficiency of an alternator/motor, for example, can reach 99%, including the refrigeration needed, compared with 92% for conventional copper based components. Wright Lab is developing both the high temperature SC materials and designs for generators, motors, actuators and power transmission lines.

Perhaps less well recognized, cryogenic cooling (i.e. to liquid Nitrogen temperatures) dramatically improve the performance of standard commercial solid state electronic components. Devices such as MOSFETS exhibit significantly reduced heating and faster switching. Ceramic capacitors have lower losses and higher capacitance when cooled.

• Batteries
— Contact Steve Vukson 937-255-7770, Dick Marsh

Aircraft battery systems are a major concern, particularly in regard to weight, reliability and maintenance. For example, vented NiCd battery maintenance costs are $3000/yr for each battery, amounting to $1/2 billion over a 20 year period. Wright Labs has developed a maintenance-free sealed NiCd cell technology, which uses low cost separator materials and which they’ve married with a microprocessor-based smart charger. These new systems will eliminate all scheduled maintenance costs, and also to save another $1/2 billion by reducing flight mission interruptions.

The bulk of the Lab’s battery program budget is devoted to advanced lithium polymer technology, doing work in molecular engineering in cooperations with Cornell, Berkeley and other academic institutions. The program has demonstrated prototype rechargeable lithium batteries with energy densities above 80 W-Hr/kg.

Thermal batteries are a special class of one-shot primary batteries used in weapons systems to deliver a large burst of power, very reliably, after waiting as long as one or two decades. Sandia National Lab is also well versed in this technology. ( –Would this have a useful role to play in nuclear power plant emergency systems?)

• Lubrication Technologies
— Contact Bob Wright, 937-255-4230, wrightrl@wl.wpafb.af.mil

This separate branch provides field support, development and advanced technology research. Their services to the Air Force include comprehensive testing facilities, bearing systems development, lubricant testing, magnetic bearings, etc.

For lubricants, increasing operating temperatures and longevity of lubricants are ever present goals. Some state-of-the-art compounds (polyphenyl ethers) have higher temperature capability but cannot be used below 40 deg. F, an obvious limitation for tactical systems. Others (perfluoro ethers) perform extremely well over a wide temperature range, but degrade quickly leading to corrosion. The overall paradigm is shifting from use of bulk oils to vapor phase lubricants, soft magnetic materials, and expendable coatings, although conventional ester lubricants are still foreseen to be the mainstay of aviation lubrication for some time to come. Meanwhile, integration of on-engine (on-line) oil condition diagnostics is an important theme. Off-line diagnostics are effective, but not optimal. This is a vital issue, as lubricant systems are implicated in 1.5 aircraft losses per year.

Magnetic Bearings — The Lab has a major development program, foreseeing big opportunities in engines to do active rotor dynamics control, increase temperature, do active control of compressor stability and blade tip clearance, and to have less logistics and better real time diagnostics.

On-line spectrometer — The Lab is sponsoring development of a very small infrared spectrometer for on-line oil analysis. The device measures the condition of the basestock and additives, and can detect the presence of unwanted contaminants, such as water, fuel, glycol, or wrong oil type.

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"RULER" — Remaining Useful Life Evaluation Routine — off-line test system measures antioxidant levels in lubricants quickly and accurately by "voltammetric analysis". Results enable operators to determine remaining useful life of lubricants in less that a minute. RULER System consists of an "RULER" — Remaining Useful Life Evaluation Routine — off-line test system measures antioxidant levels in lubricants quickly and accurately by "voltammetric analysis". Results enable operators to determine remaining useful life of lubricants in less that a minute. RULER System consists of an instrument with probe, R-DAS (RULER Data Acquistion Software) pre-installed on a desktop or laptop computer. RULER System cost about $15,000. Proprietary solvents are used in the tests.

The RULER was originally developed at the University of Dayton Research Institute for Wright-Patterson Labs, for quick tests on aircraft oils between missions. It is manufactured by Fluitec Ltd., based in Dayton, OH with operations in Brussels. RULER customers cover a large range of industries world wide in oil, additive, manufacturing plants, power generation, aerospace and fleets. It’s applied to turbine, hydraulic, synthetic, working fluid, IC engine, and even biodegradable oils.

Contact: Lawrence Contreras, Fluitec, 937-223-8602, lcontrerasjr@juno.com

NACE – Int’l Corrosion Society

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NACE Annual Conference and Exposition — CORROSION/98
March 22 – 27, 1998 San Diego, CA

See website at http://www.nace.org

A brochure for this conference came in the mail recently.

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In the unlikely event that there could be people in your company who ought to be involved with NACE and aren’t, some background information is included below. (I checked with the NACE membership office, and several UFTO companies do have individuals who are members, though some have only one or two, and some have none.)

NACE is to corrosion what IEEE is to electrical engineering, and is one of those exceptional independent resources in a particular technical area of importance to the industry.

UFTO is developing information on other such resources as well.

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(excerpts from the NACE website)

NACE International – The International Corrosion Society
1440 South Creek Drive
Houston, Texas 77084
281-228-6200 fax 281-228-6300

Mission ——–
NACE International is a professional technical society dedicated to reducing the economic impact of corrosion, promoting public safety, and protecting the environment by advancing the knowledge of corrosion engineering and science. With more than fifty years of experience in developing corrosion prevention and control standards, NACE International has become the largest organization in the world committed to the study of corrosion.

Membership ——–
NACE’s membership has grown to more than 15,000 professionals from eighty nations representing virtually every major industry. NACE’s membership is comprised of: engineers, inspectors, and technicians; presidents, business owners, and consultants; managers, supervisors, and sales representatives; scientists, chemists, and researchers; and educators and students.

Organizational Structure ——–
NACE is organized into four Areas in North America and four Regions outside the continent. More than eighty sections within these Areas and Regions sponsor local programs to promote the exchange of corrosion information throughout the world.

Conferences ——–
Each year, NACE sponsors a number of conferences, regional symposia, and expositions. NACE’s annual conference is the world’s largest gathering dedicated to the control and prevention of corrosion. This event attracts more than 5,000 attendees each year and is comprised of technical symposia, research sessions, technical committee meetings, current issue presentations, informative lectures, and a comprehensive four-day exhibition.

Education Courses ——–
NACE offers education programs for both members and nonmembers in the US, Canada, and a variety of international locations. Intensive week-long courses are developed and taught by corrosion professionals with years of practical experience in the field. A variety of other corrosion topics are covered in short courses, TechEdge programs, in-house training programs, and video courses.

Coating Inspector Training and Certification Program ——–
NACE’s Coating Inspector Training and Certification Program was developed to meet the coatings industry need for recognized professional training standards and application guidelines.

Professional Recognition Program ——–
More than 4,500 individuals worldwide have been certified in corrosion science and technology

Public Affairs ——–
NACE raises the awareness of corrosion control and prevention technology among government agencies and legislators, businesses, professional societies, and the general public.

Standards ——–
NACE’s Technical Practices Committee oversees more than 300 technical committees that research, study, and recommend state-of-the-art corrosion technologies to both the public and private sectors. These committees produce consensus industry standards in the form of test methods, recommended practices, and material requirements. Industries and governments across the globe rely on NACE standards for materials preservation and corrosion control information.

Publications ——–
– Materials Performance, a monthly journal that publishes practical corrosion control applications and case histories for solving corrosion-related problems affecting all industries.

– Corrosion Journal, a monthly technical research journal devoted to taking a critical look at the causes and effects of corrosion processes and the protection of materials in corrosive environments.

– Corrosion Abstracts, a bimonthly reference periodical providing more than 500 abstracts of corrosion-related publications per issue from the world’s leading technical journals and book publishers.

Software ——–
NACE packages the latest in corrosion technology in easy-to-use desktop software programs. Data selection and reference software programs assist engineers with researching, analyzing, and developing advanced corrosion control systems.

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Energy Technology Committees

Corrosion and materials degradation control in the generation, conversion, and utilization of energy.

— T-2-4 Material Performance in Power T&D Systems
To facilitate identification and resolution of corrosion-related problems with components of power transmission and distribution systems. The components to be considered are: hardware, conductors, insulators, structures, stations, and other aboveground equipment.

— T-2A Nuclear Systems
To provide scientific and engineering information concerning the performance of materials exposed to environments related to any phase of the generation of energy originating from a nuclear source, and of materials used for disposal of spent nuclear fuels and radioactive wastes.

— T-2A-2 Interim Storage of Radioactive Liquid Waste
To examine corrosion of radioactive liquid waste storage and transfer systems. This assignment includes material selection, corrosion monitoring, control, and research activities associated with the interim storage of radioactive liquid wastes and their impact on safety and the environment. Specific areas of interest include: life prediction, corrosion surveillance, corrosion control, degradation mechanisms, and tank structural integrity.

— T-2E Geothermal Systems
To identify methods and materials for the control of degradation proceses in the extraction, conversion, and utilization of geothermal resources.

— T-2F Fossil Fuel Combustion and Conversion
Materials performance in the generation and utilization of energy derived from combustion of fossil fuels and in systems converting fossil fuels into gaseous and liquid products. Areas of coverage are fireside combustion systems, including waste incineration. In the synfuels sector, areas covered are coal conversion (gasification; liquefaction) and extraction of oil from tar sands (bitumens) and shale.

T-2F-1/T-5-1 Materials Problems in Waste Incinerator Fireside and Air Pollution Control Equipment
To provide a forum for exchange of information on the performance of materials in incineration facilities for chemical, municipal, and toxic wastes, and combustion facilities for low-grade and biomass fuels. Scope encompasses associated energy recovery and emission control systems.