By 2030, it is expected that 80% of all electric power will flow through power electronics systems. Wide bandgap power modules that can tolerate higher voltages and currents than silicon-based modules are the most promising solution to reducing the size and weight of power electronics systems. These wide-bandgap power modules constitute powerful building blocks for power electronics systems, and wide bandgap-based converter/power electronics building blocks are envisaged to be widely used in power grids in low- and medium-voltage applications and possibly in high-voltage applications for high-voltage direct current and flexible alternating current transmission systems. One of the merits of wide bandgap devices is that their slew rates and switching frequencies are much higher than silicon-based devices. However, from the insulation side, frequency and slew rate are two of the most critical factors of a voltage pulse, influencing the level of degradation of the insulation systems that are exposed to such voltage pulses. The shorter the rise time, the shorter the lifetime. Furthermore, lifetime dramatically decreases with increasing frequency. Thus, although wide bandgap devices are revolutionizing power electronics, electrical insulating systems are not prepared for such a revolution; without addressing insulation issues, the electronic power revolution will fail due to dramatically increased failure rates of electrification components. In this regard, internal partial discharges (PDs) have the most effect on insulation degradation. Internal PDs which occur in air-filled cavities or voids are localized electrical discharges that only partially bridge the insulation between conductors. Voids in solid or gel dielectrics are challenging to eliminate entirely and may result simply during manufacturing process. The objective of this study is to develop a Finite-Element Analysis (FEA) PD model under fast, repetitive voltage pulses, which has been done for the first time. The model is coded and implemented in COMSOL Multiphysics linked with MATLAB, and its simulation results are validated with experimental tests. Using the model, the influence of different parameters including void shape, void size, and void air pressure on PD parameters are studied. / M.S. / To decarbonize and reduce energy consumption for commercial aviation, the development of lightweight and ultra-efficient all-electric powertrain including electric motors, drives, and associated thermal management systems has been targeted. Using wide bandgap (WBG) power modules that can tolerate high voltages and currents can reduce the size and weight of the drive. However, the operation of WBG-based power converter can endanger the reliability of the electrified systems, most importantly, the insulation system. In this study, it is attempted to model the impact of such threats to the insulation system using numerical models.

In recent years, triply periodic minimal surfaces (TPMS) have drawn much attention in research mainly due to their smooth, highly symmetrical surfaces, non-self-intersecting features, and mathematically controllable topologies. TPMS can have pre-defined physical and mechanical properties. The advancement of additive manufacturing technology enables us to fabricate these intricate geometric structures which was not possible by traditional manufacturing methods. In this study, the vat photopolymerization technique was used to manufacture Primitive, Gyroid, and Diamond structures. Samples were cured under ultraviolet (UV) rays after printing. Uniaxial compression experiments were conducted to assess the compressive modulus and strength of these lightweight structures. The compressive behavior of TPMS structures was also predicted using finite element analysis (FEA). Dynamic mechanical analysis (DMA) was used to compare the behavior of these structures at different temperatures. UV-cured samples exhibited improved thermo-mechanical characteristics. The primitive structure had the highest compressive strength among other structures. FEA also revealed the stress concentration areas for each sandwich structure. The DMA findings indicate that TPMS sandwich structures demonstrate significantly reduced storage modulus compared to solid structures. A numerical investigation was performed to understand the heat exchanger application of TPMS structures. The velocity profile, temperature, and pressure distributions were observed for the Primitive heat exchanger. The results of this investigation provide valuable information regarding the enhanced structural and thermal characteristics of these structures manufactured using vat photopolymerization.

The Habitable Worlds Telescope Starshade is an occulting disk that orbits in tandem with a telescope that occludes and diffuses the light from stars to observe the relatively dim exoplanets in orbit around them. It achieves this in part with tailored petals that diffuse light to soften the light from the star. Due to the relative sizes of the star and the planet, NASA considers the shape stability of the Starshade's petals to be a Key Technology Gap. The Starshade is developed to be a deployable composite structure that folds on itself to fit within modern rockets. Due to the nature of satellite launches, Starshade will sit in the stowed configuration for multiple years, during which the viscoelastic material properties of the materials that consist of the Starshade will deform in the structure and take an unknown time to recover fully. Thus, the need arises to understand Starshade's viscoelastic behavior through recovery after fully deploying. Starshade's Petals consists of a sandwich composite structure where multiple composite edges are joined together using a significantly less stiff adhesive that is comparably thicker than the individual Carbon Fiber Reinforced Plastic layers that consist of the composite edge. This could cause traditional modeling approaches to not fully capture the potential modes of relaxation in the structure, so a diagnostic model, referred to as the Phoenix Edge, is developed to compare different modeling techniques. After modeling techniques are validated against each other, they are applied to the NI2 Petal to predict the viscoelastic structural response through 6 months of recovery after three years of stowage in a furled configuration.

Finite element modeling (FEM) is used to predict complex phenomena like part deformation and the formation of residual strain resulting from cyclical heating. A gap exists in current literature using FEM to investigate the effect of printing strategies on strain and deformation in Ti-6Al-4V NIST bridges built by laser powder bed fusion (L-PBF). This study compares thermomechanical finite element models incorporating three scan strategies commonly used in literature: meander, stripe, and checkerboard, for the fabrication of Ti-6Al-4V NIST bridges using L-PBF. FEM of each scan strategy uses four mechanical material models: elastic perfectly plastic, Johnson-Cook, eigenstrain, and Hill 1948. The models’ mechanical responses are compared to experimental data. The objective of this work is to compare the predicted strain states, part deflections, and runtimes for each scan strategy and mechanical material model. Ultimately, this work aims to use FEM to predict challenges from the as-printed stress state of the L-PBF part.

No / The pharmaceutical powder and tableting process is simulated using a combined finite-discrete element method and contact dynamics for irregular-shaped particles. The particle-scale formulation and two-stage contact detection algorithm which has been developed for the proposed method enhances the overall calculation efficiency for particle interaction characteristics. The irregular particle shapes and random sizes are represented as a pseudo-particle assembly having a scaled up geometry but based on the variations of real powder particles. Our simulations show that particle size, shapes and material properties have a significant influence on the behaviour of compaction and deformation.

Recently planar magnetic technologies have been widely used in power electronics, due to good cooling and ease of fabrication. High frequency operation of magnetic components is a key to achieve high power density and miniaturization. However, at high frequencies, skin and proximity effect losses in the planar windings become significant, and parasitics cannot be ignored. This piece of work deals with the modeling and design of planar integrated magnetic component for power electronics applications. First, one-dimensional eddy current analysis in some simple winding strategies is discussed. Two factors are defined in order to quantify the skin and proximity effect contributions as a function of frequency. For complicated structures, 2D and 3D finite element analysis (FEA) is adopted and the accuracy of the simulation results is evaluated against exact analytical solutions. Then, a planar litz structure is presented. Some definitions and guidelines are established, which form the basis to design a planar litz conductor. It can be constructed by dividing the wide planar conductor into multiple lengthwise strands and weaving these strands in much the same manner as one would use to construct a conventional round litz wire. Each strand is subjected to the magnetic field everywhere in the winding window, thereby equalizing the flux linkage. 3D FEA is utilized to investigate the impact of the parameters on the litz performance. The experimental results verify that the planar litz structure can reduce the AC resistance of the planar windings in a specific frequency range. After that, some important issues related to the planar boost inductor design are described, including core selection, winding configuration, losses estimation, and thermal modeling. Two complete design examples targeting at volume optimization and winding parasitic capacitance minimization are provided, respectively. This work demonstrates that planar litz conductors are very promising for high frequency planar magnetic components. The optimization of a planar inductor involves a tradeoff between volumetric efficiency and low value of winding capacitance. Throughout, 2D and 3D FEA was indispensable for thermal & electromagnetic modeling. / Master of Science

In American rail operations, rails fail due to the combined effects of rail wear due to repetitive wheel contact and the growth of surface and sub-surface cracks and flaws. Rail maintenance includes frequent uncoupled wear and ultrasonic inspections that determine the amount of wear that the rail has undergone and the presence of cracks and flaws. A rail is removed from service when its wear reaches a pre-determined wear limit or a flaw is detected in its cross section. In rail research, the life of a rail is typically estimated using fracture mechanic or fatigue methods and an assumed flaw geometry. Multiple models ranging from complex elastic-plastic finite element models to simplified representations of a beam on an elastic foundation have been developed to predict the life of a rail. The majority of rail failure models do not incorporate rail wear into their analysis, and assume an unworn rail geometry. In order to account for rail wear, certain models adopt simplified rail geometries that uncouple rail wear into top-wear and side-wear. This thesis presents a rail failure model that describes the combined effects of rail wear and crack growth through the development of a functional relationship between input variables describing the geometry, loading, and material properties of a given rail and output variables describing the life characteristics of the rail. This relationship takes the form of multiple response surfaces estimating the desired output variables. Finite element models incorporating worn rail profiles and an assumed crack geometry corresponding to a detail fracture are combined to determine the state of stress and strain at the assumed flaw. Strain-life fatigue methods and fracture mechanic concepts are used to develop the output variables necessary to describe the life of the rail using the finite element model results. The goals of this research are to predict the remaining fatigue life and estimate the crack-growth rate of the rail based on the minimum number of geometry, loading, and material property independent variables. The outputs developed to describe the rail's remaining life are intended to be used for the decision making for rail removal. / Master of Science

This master's thesis is focused on the structural response due to blast loading, where the geometry used was arbitrary but heavily inspired by Siemens Energy. The aim of the thesis is to gain a better understanding on how to model the blast load and how it affects the structure, as well as to study the modeling of bolts with both pre-tension and a damage criteria in an explicit analysis. Lastly, the importance of strain rate dependent material models was studied. Other aspects such as mass scaling and Rayleigh damping were also investigated. The software used to solve these tasks were Hypermesh, Abaqus and Python. To conclude, the conclusions drawn from this thesis was that bolts should be modeled using connector elements, and including pre-tension is more conservative than not using it for the case studied. However, for the material modeling it gives more conservative results when using a strain rate independent material model compared to the strain rate dependent model, and is advised to be used in the future.

This dissertation focuses on studying membrane air dehumidification for a membrane moisture exchanger in a membrane heat pump system. The study has two parts: an optimization of membrane moisture exchanger for air dehumidification in the macroscale, and diffusion of water vapor in polymer nanocomposites membrane for humid air dehumidification in the nanoscale. In the first part of the research, the mass transport of water vapor molecules through hydrophilic silica nanochannel chains in hydrophobic polyurethane matrix was studied by simulations and experiments for different membrane moisture exchanger design configurations. The mass transport across the polymer nanocomposite membrane occurs with the diffusion of moist air water vapor molecules in the membrane moisture exchanger in a membrane heat pump air conditioning system for air dehumidification purposes. The hydrophobic polyurethane matrix containing the hydrophilic silica nanochannel chains membrane is responsible for transporting water vapor molecules from the feed side to the permeate side of the membrane without allowing air molecules to pass through.In the second part of the research, diffusion analysis of the polymer nanocomposite membrane were performed in the nanoscale for the polymer nanocomposite membrane. The diffusion phenomena through the polymer, the polymer nanocomposite without modifying the silica surfaces, and the polymer nanocomposite with two different silica modified surfaces were studied in order to obtain the highest water vapor removal through the membrane. Different membrane moisture exchanger configurations for optimal water vapor removal were compared to get the desired membrane moisture exchanger design using the finite element method (FEM) with the COMSOL Multiphysics software package. The prediction of mass transport through different membrane configurations can be done by obtaining the mass flux value for each configuration. An experimental setup of one membrane moisture exchanger design was introduced to verify the simulation results. Also, for different membrane structures, permeability was measured according to the ASTM E-96 method. The prediction of water vapor diffusion through the polymer nanocomposite was studied by molecular dynamics simulation with the MAPS 4.3 and LAMMPS software packages. As a new nanocomposite material used in air dehumidification application, water vapor diffusivity through Silica-Polyurethane nanocomposite membranes was measured by the random movement of water vapor molecules through the formed nanochannels in the nanocomposite. For the diffusivity value, the Einstein's relationship was employed for the movement of each single water vapor molecule during the simulation time for all suggested membranes. The results of the proposed research will contribute to enhancing the energy efficiency of air conditioning systems by choosing the membrane moisture exchanger configuration which maximizes water vapor removal while, at the same time, enhancing the silica surfaces with the desired surface modifier that will maximize diffusion through the membrane itself.

Magnetic field-assisted freeze-casting was used to create porous B4C ceramic preforms. An optimum slurry consisted of a mixture of B4C powders with 6 wt.% Er2O3 powder in an H2O-PVA solution and was cooled at a rate of 1 °C/min from room temperature to -30 °C resulting in porous green state ceramic preform with vertical channels. The Er2O3 powder was added to improve the magnetic response of the slurry. The preform was then sublimated to remove H2O and then sintered. The sintered ceramic preform was then infiltrated in the most vertically aligned channel direction with molten Al (A356) metal through a vacuum-assisted pump to create the metal matrix composite (MMC). Finite element analysis simulations were used to analyze and predict the anisotropic effect of B4C channel alignment on mechanical properties. The mechanical properties of the composite were then experimentally found via compression testing, which was compared with rule-of-mixtures and finite element modeling simulations, to analyze the effect of anisotropy due to magnetic field-assisted freeze-casting. This study reinforces the viability of cost-effective magnetic field-assisted freeze-casting as a method to create highly directional ceramic preforms, which can be subsequently metal infiltrated to produce MMCs with highly anisotropic toughness.