TECHNICAL POINT OF CONTACT (TPOC)
Sandler Belizaire
Michael Allen
John Colbert
Ricardo Rodriguez Cruz
PROJECTED CMMC LEVEL REQUIREMENT
Level 2 (Self)
TECHNOLOGY AREAS
None
MODERNIZATION PRIORITIES
Directed Energy (DE)
KEYWORDS
Inductor; nanocrystalline; electromagnetic interference filter; high frequency; electrical power system; aerospace
OBJECTIVE
Design, develop, test, and deliver a lightweight, high power, high frequency bandwidth, common mode voltage cancellation (CMVC) electromagnetic interference (EMI) filter optimized for aerospace power generation applications.
DESCRIPTION
The U.S. Navy is embarking on opportunities for increased aerospace platform electrification to meet its unique demands on aircraft power and propulsion systems which drives a significant need for increased power density and high temperature components. A key enabler is wide bandgap (WBG) device-based power conversion. These technologies bring significant benefits to improving fielded aerospace electrical power system challenges while also driving towards new advanced platform capabilities. However, they also bring a new set of significant challenges, namely electromagnetic interference (EMI) and electromagnetic compatibility (EMC) which, if not mitigated properly, may lead to avionics or mission system degradation jeopardizing the platform's warfighting mission readiness.
Nanocrystalline materials are an emerging technology that provide opportunity to bring significant weight savings to common mode (CM) inductors due to its high saturation flux density, high temperature capability, and low core losses. While existing COTS nanocrystalline magnetic cores have mainly focused on high power, low frequency (i.e., industrial drives) or low power, high frequency (i.e., radio frequency system) applications, the Navy requires high power and high frequency bandwidth nanocrystalline cores to achieve desired filter attenuation performance and power density requirements for military aerospace applications. In many cases, the components required for these aerospace applications (e.g., tactical fighter aircraft or future hybrid electric/fully electric aircraft) differ significantly from existing COTS components required for commercial electric vehicle markets due to the higher power, increased power density, and more stringent EMI requirements in the military aerospace environment.
This topic is focused on maturation of the materials and components to enable development of system level filter hardware solutions that are reliable and maintain high performance response for military aerospace applications, with option for commercial use, as documented in DO-160 and MIL-STD-461 for EMI performance.
The solution should demonstrate a greater than 50% weight reduction compared to commercial off-the-shelf (COTS) CMVC filters and inductor components through the development and use of customized high power and high frequency bandwidth nanocrystalline core materials.
PHASE I
For a Direct to Phase II topic, the Government expects that the small business will have accomplished the following in a Phase I-type effort and developed a concept for a workable prototype or design to address, at a minimum, the basic requirements of the stated objective above. The following actions would be required to satisfy the requirements of Phase I:
The Government expects that the small business will be able to demonstrate experience in the development, manufacture, and test of passive nanocrystalline magnetic core materials across various end-use applications. The small business should include skills and expertise necessary to support advanced research and development in the materials and understand development and integration into CMVC EMI filter devices.
FEASIBILITY DOCUMENTATION: Offerors interested in participating in Direct to Phase II must include in their response to this topic Phase I feasibility documentation that substantiates the scientific and technical merit and Phase I feasibility described in Phase I above has been met (i.e., the small business must have performed Phase I-type research and development related to the topic NOT solely based on work performed under prior or ongoing federally funded SBIR/STTR work) and describe the potential commercialization applications. The documentation provided must validate that the proposer has completed development of technology as stated in Phase I above.
PHASE II
Focus on research and development toward significant material and component-level improvements of passive high power and high frequency bandwidth nanocrystalline core materials that enable system level reductions in Size, Weight, Power, and Cooling (SWaP-C) of a CMVC EMI filter for aerospace power generation applications. Develop designs that consider requirements set forth in both DO-160 and MIL-STD-461 for EMI performance. Consider innovative design methodologies and experimentation to mature the CMVC EMI filter technology to a minimum of TRL 5 through testing and demonstration in a lab environment as a threshold requirement. Conduct required additional testing and demonstration to TRL 6 in a relevant end-use application environment. Deliver a minimum of two CMVC EMI filter units with the expected greater than 50% weight reduction in comparison to existing COTS designs with demonstrated significant improvements in filter attenuation.
PHASE III DUAL USE APPLICATIONS
Deliver flight-representative prototype CMVC EMI filters for integration into a selected aerospace generator or power system with planned integrated system test, ground test, and flight test.
High power, high frequency, nanocrystalline core materials and filter components have opportunity for dual-use applications in commercial aerospace that have similar rigorous SWaP-C and EMI/EMC demands.
REFERENCES
Cai, Mingjuan et al. Obtaining extremely low coercivity of high Bs FeCoBSiCPCu nanocrystalline alloys through modulation of magnetic anisotropy. Journal of Materials Science and Technology, 29 January 2024. https://smse.seu.edu.cn/_upload/article/files/7c/18/5203da8f45b9b6e5aa132409a854/61d634fe-1bad-47cf-a170-3390c1d26b07.pdf
Theisen, E.A. "Recent Advances and Remaining Challenges in Manufacturing of Amorphous and Nanocrystalline Alloys." IEEE Transactions on Magnetics, vol. 58, no. 8, pp. 1-7, Aug. 2022, Art no. 2001207. doi: 10.1109/TMAG.2022.3163713 https://ieeexplore.ieee.org/document/9747939/
Li, Y et al. "A Novel Hybrid Magnetic Core Design Method for Weight Reduction of Wireless Power Transfer Systems," 2024 IEEE Applied Power Electronics Conference and Exposition (APEC), Long Beach, CA, USA, 2024, pp. 1202-1206. doi: 10.1109/APEC48139.2024.10509336 https://ieeexplore.ieee.org/iel7/10509012/10509018/10509336.pdf
Ojeda-Rodr guez, A. et al. "Simple and Accurate Characterization of Nanocrystalline Common Mode Chokes." 2022 IEEE International Symposium on Electromagnetic Compatibility & Signal/Power Integrity (EMCSI), Spokane, WA, USA, 2022, pp. 472-477. doi: 10.1109/EMCSI39492.2022.9889371 https://ieeexplore.ieee.org/document/9889371
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