Lifetime estimation of IGBT module using square-wave loss discretization and power cycling test

The insulated gate bipolar transistor(IGBT)module is one of the most age-affected components in the switch power supply, and its reliability prediction is conducive to timely troubleshooting and reduction in safety risks and unnecessary costs. The pulsed current pattern of the accelerator power supply is different from other converter applications;therefore, this study proposed a lifetime estimation method for IGBT modules in pulsed power supplies for accelerator magnets. The proposed methodology was based on junction temperature calculations using square-wave loss discretization and thermal modeling.Comparison results showed that the junction temperature error between the simulation and IR measurements was less than 3%. An AC power cycling test under real pulsed power supply applications was performed via offline wearout monitoring of the tested power IGBT module. After combining the IGBT4 PC curve and fitting the test results,a simple corrected lifetime model was developed to quantitatively evaluate the lifetime of the IGBT module,which can be employed for the accelerator pulsed power supply in engineering. This method can be applied to other IGBT modules and pulsed power supplies.

Ex⁃situ Measurement of Internal Deformation in Ball Grid Array Package with Digital Volume Correlation

In spacecraft electronic devices,the deformation of solder balls within ball grid array(BGA)packages poses a significant risk of system failure.Therefore,accurately measuring the mechanical behavior of solder balls is crucial for ensuring the safety and reliability of spacecraft.Although finite element simulations have been extensively used to study solder ball deformation,there is a significant lack of experimental validation,particularly under thermal cycling conditions.This is due to the challenges in accurately measuring the internal deformations of solder balls and eliminating the rigid body displacement introduced during ex-situ thermal cycling tests.In this work,an ex-situ three-dimensional deformation measurement method using X-ray computed tomography(CT)and digital volume correlation(DVC)is proposed to overcome these obstacles.By incorporating the layer-wise reliability-guided displacement tracking(LW-RGDT)DVC with a singular value decomposition(SVD)method,this method enables accurate assessment of solder ball mechanical behavior in BGA packages without the influence of rigid body displacement.Experimental results reveal that BGA structures exhibit progressive convex deformation with increased thermal cycling,particularly in peripheral solder balls.This method provides a reliable and effective tool for assessing internal deformations in electronic packages under ex-situ conditions,which is crucial for their design optimization and lifespan predictions.

Enhancing fatigue performance of AZ31 magnesium alloy components fabricated by cold metal transfer-based wire arc directed energy deposition through LPB

Cold Metal Transfer-Based Wire Arc Directed Energy Deposition(CMT-WA-DED)presents a promising avenue for the rapid fabrication of components crucial to automotive,shipbuilding,and aerospace industries.However,the susceptibility to fatigue of CMT-WA-DED-produced AZ31 Mg alloy components has impeded their widespread adoption for critical load-bearing applications.In this study,a comprehensive investigation into the fatigue behaviour of WA-DED-fabricated AZ31 Mg alloy has been carried out and compared to commercially available wrought AZ31 alloy.Our findings indicate that the as-deposited parts exhibit a lower fatigue life than wrought Mg alloy,primarily due to poor surface finish,tensile residual stress,porosity,and coarse grain microstructure inherent in the WA-DED process.Low Plasticity Burnishing(LPB)treatment is applied to mitigate these issues,which induce significant plastic deformation on the surface.This treatment resulted in a remarkable improvement of fatigue life by 42%,accompanied by a reduction in surface roughness,grain refinement and enhancement of compressive residual stress levels.Furthermore,during cyclic deformation,WA-DED specimens exhibited higher plasticity and dislocation density compared to both wrought and WA-DED+LPB specimens.A higher fraction of Low Angle Grain Boundaries(LAGBs)in WA-DED specimens contributed to multiple crack initiation sites and convoluted crack paths,ultimately leading to premature failure.In contrast,wrought and WA-DED+LPB specimens displayed a higher percentage of High Angle Grain Boundaries(HAGBs),which hindered dislocation movement and resulted in fewer crack initiation sites and less complex crack paths,thereby extending fatigue life.These findings underscore the effectiveness of LPB as a post-processing technique to enhance the fatigue performance of WA-DED-fabricated AZ31 Mg alloy components.Our study highlights the importance of LPB surface treatment on AZ31 Mg components produced by CMT-WA-DED to remove surface defects,enabling their widespread use in load-bearing applications.

Ex situ aging effect on sulfonated poly(ether ether ketone) membrane:Hydration-dehydration cycling and hydrothermal treatment

Prolonged hydrothermal treatment for sulfonated poly(ether ether ketone) membranes induces mechanical degradation and developing hydrophilic-hydrophobic phase separation, simultaneously. The enhanced phase separation provides incremental proton conductivity to the membranes, whereas mechanical degradation drastically reduces device stability. On this basis, we describe here the effects of two different ex situ aging processes on sulfonated poly(ether ether ketone) membranes: hydrationdehydration cycling and prolonged hydrothermal treatment. Both aged membranes exhibited enhanced phase separation under the hydrated conditions, as characterized by small angle X-ray scattering.However, when the aged membranes were dried again, the nanostructure of the membranes aged via the hydration-dehydration cycling was recoverable, whereas that of the membranes aged via prolonged hydrothermal treatment was irreversible. Furthermore, the two differently aged membranes showed clear differences in thermal, mechanical, and electrochemical properties. Finally, we implemented both aged membranes in fuel cell application. The sample aged via hydration-dehydration cycling maintained its improved cell performance, whereas the sample aged via hydrothermal treatment showed drastically reduced cell performance after durability test for 50 h.

Impact of Freeze-Thaw Cycles on Compressive Characteristics of Asphalt Mixture in Cold Regions

Low average temperature, large temperature difference and continual freeze-thaw （F-T） cycles have significant impacts on mechanical property of asphalt pavement. F-T cycles test was applied to illustrate the mixtures＇ compressive characteristics. Exponential model was applied to analyze the variation of compressive characteristics with F-T cycles; Loss ratio model and Logistic model were used to present the deterioration trend with the increase of F-T cycles. ANOVA was applied to show the significant impact of F-T cycles and asphalt- aggregate ratio. The experiment results show that the compressive strength and resilient modulus decline with increasing F-T cycles; the degradation is sharp during the initial F-T cycles, after 8 F-T cycles it turns to gentle. ANOVA results show that F-T cycles, and asphalt-aggregate ratio have significant influence on the compressive characteristics. Exponential model, Loss ratio model and Logistic model are significantly fitting the test data from statistics view. These models well reflect the compressive characteristics of asphalt mixture degradation trend with increasing F-T cycles.

Shape-stablized EP/Paraffin Composite for Latent Heat Storage

620# and 56# paraffin mixtures were impregnated into expanded perlite （EP） by vacuuming method. Effects of impregnation with/without vacuum, vacuuming time, and thermal cycles were discussed. The appropriate mass fraction of paraffin mixture in the composite and vacuuming time were found respectively to be 80% and 20 min. Fourier transform infrared spectrometer （FT-IR） analysis shows that it has a good compatibility between paraffin mixture and EP. From differential scanning calorimetry （DSC） analysis, the latent heat of EP/Paraffin mixture composite is almost linearly related with the mass fraction of paraffin mixture in the composite. After 100 thermal cycles, the deviation of phase change temperatures is acceptable, but more deviation of latent heat appears. The calcium stearate dispersing granule coated by epoxy resin can effectively lower leakage during thermal cycles.

A method for computing unsupported roof distance in roadway advancement and its in-situ application

A reasonable unsupported roof distance(URD) when advancing underground coal mine roadways can contribute greatly to safe and rapid roadway development.A mechanical model of the roof,using the relationship between the roof stress distribution and URD,obtained by the difference method,and roof stability according to the in-situ roof stress and rock mass strength was developed.We subsequently designed a proper range of URD,developed a testing method of URD with the function of mining protection,evaluated roof stability through analyzing the test data and then determined a reasonable URD.Considering the factors of the geological conditions,the immediate roof stability and the efficiency of the labor arrangement system,the URD of the advancing roadway of 9802 working face in Zhangshuanglou coal mine was determined to be 6 m using the proposed method.The results show that,when a 2 m length of roadway was reinforced by temporary support and high pre-stressed bolt support after the roadway advancement of 6 m per cycle,the speed and the security of the roadway development can be achieved and the advance rate can reach more than 400 m per month.

High-Speed EMU TCMS Design and LCC Technology Research

This paper introduces the high-speed electrical multiple unit （EMO） life cycle, including the design, manufacturing, testing, and maintenance stages. It also presents the train control and monitoring system （TCMS） software development platform, the TCMS testing and verification bench, the EMU driving simulation platform, and the EMU remote data transmittal and maintenance platform. All these platforms and benches combined together make up the EMU life cycle cost （LCC） system. Each platform facilitates EMU LCC management and is an important part of the system.

Effects of zinc on static and dynamic mechanical properties of copper-zinc alloy

The effects of adding alloy element zinc on the static and dynamic mechanical properties of copper-zinc alloy were investigated. Tensile and low cycle fatigue behaviors of the C11000 copper and H63 copper-zinc alloy were obtained by using a miniature tester that combined the functions of in situ tensile and fatigue testing. A piezoelectric actuator was adopted as the actuator for the fatigue testing, and the feasibility of the fatigue actuator was verified by the transient harmonic response analysis based on static tensile preload and dynamic sinusoidal load. The experimental results show that the yield strength and tensile strength of the C11000 copper are improved after adding 37%(mass fraction) zinc, and H63 copper-zinc alloy presents more obvious cyclic hardening behavior and more consumed irreversible plastic work during each stress cycle compared with C11000 copper for the same strain controlled cycling. Additionally, based on the Manson-Coffin theory, the strain-life equations of the two materials were also obtained. C11000 copper and H63 copper-zinc alloy show transition life of 16832 and 1788 cycles, respectively.

EFFECT OF FABRICATION ON HIGH CYCLE FATIGUE PROPERTIES OF COPPER THIN FILMS

The influence of fabrication on the tensile and fatigue behavior of copper films manufactured by 3 kinds of fabrication methods was investigated. The tensile and high cycle fatigue tests were performed using the test machine developed by authors. Young＇s moduli （72, 71 and 69 GPa, respectively） are lower than the literature values （108-145 GPa）, while the yield strengths were as high as 358, 350 and 346 MPa, respectively and the ultimate strengths as 462, 456 and 446 MPa, respectively. There is not much difference in the tensile properties of the 3 kinds of films. There is little difference in the fatigue properties of the 3 kinds of films but one of them has shorter fatigue life than others in high cycle region and longer fatigue life than others in low cycle region.

Emission Performance of Motorcycles in Real-Road Conditions

WMTC,which means a worldwide motorcycle testing cycle,is now regarded as the most possible choice for the global motorcycle emission testing cycle,but whether or not it can be used in China is still unknown.In this study,a large number of data on the speed-time trace of motorcycles were sampled from various kinds of roads in 5 cities in China.Based on a series of criterion numbers defined,the driving character of motorcycles in the real-road conditions of China was obtained.With the aid of a specially designed program,an emission testing cycle that can indicate the driving characteristics of motorcycle in the real-road conditions was synthesized,and the exhaust emission tests of 20 motorcycles under the synchronized cycle and WMTC were carried out based on a CVS system and a motorcycle chassis dynamometer.The results show that although there do exist differences in some criterion numbers between the real-road condition and WMTC,such as proportion of idling mode,mean speed,mean running speed and the average acceleration and deceleration rates,the driving behaviors are similar.The results of exhaust emission tests indicate that the emission values of motorcycles under the synchronized cycle and WMTC have a relatively strong correlation.This means that WMTC can be introduced as a standard motorcycle emission test regulation into China.

Hybridisation Potentials for Heavy Trucks Considering Route Topography

Based on dynamometer test cycles or plain motorway operation, heavy truck hybridisation must be considered as uneconomic if only the kinetic vehicle energy can be recuperated. In mountainous regions, micro hybridization by a 48V-belt generator or mild parallel hybridisation by a large high voltage electric drive can result in considerable fuel consumption savings as well as additional benefits for heavy load utility vehicles. Additional electric power and battery size are still critical design parameters as well as critical cost factors considering the limited space and depreciation time as well as the need for maximum payload. Based on vehicle model simulations, this contribution quantifies fuel consumption savings, recuperation energy harvesting and battery requirements for different truck sizes with test cycles based on realistic route topography. The main route topography parameter for the recuperation benefit is the effective incline that integrates all downhill sections that overcompensates the vehicle resistance by tire friction and air resistance. The simulation parameter studies lead to an analytical benefit estimation, based on load cycle parameters like effective velocity, effective incline as well as the vehicle parameters mass, drag coefficient and cross sectional area. Thus, the return on investment can be assessed by an analytic rule of thumb, based on tracked cycles of existing vehicles.

Vehicles PEMFC Power System Mathematical Model for Integrated Design

In this paper, the mathematical dynamical model of a PEMFC （proton exchange membrane fuel cells） stack, integrated with an automotive synchronous electrical power drive, developed in Matlab environment, is shown. Lots of simulations have been executed in many load conditions. In this paper, the load conditions regarding an electrical vehicle for disabled people is reported. The innovation in this field concerns the integration, in the PEMFC stack mathematical dynamic model, of a synchronous electrical power drive for automotive purposes. Goal of the simulator design has been to create an useful tool which is able to evaluate the behaviour of the whole system so as to optimize the components choose. As regards the simulations with a synchronous electrical power drive, the complete mathematical model allows to evaluate the PEMFC stack performances and electrochemical efficiency.

自组装FeRu双金属纳米催化剂在可逆固体氧化物电池中实现高效稳定的CO-CO_(2)相互转化

本文报道了一种适应于高效稳定的CO-CO_(2)相互转化的可逆固体氧化物电池(RSOC)相变燃料电极.该燃料电极由FeRu双金属纳米催化剂和Ruddlesden-Popper相Pr_(0.8)Sr_(1.2)Fe_(1-x-y)Ru_(x)Mo_(y)O_(4)氧化物复合而成(FeRu@PSFRM).固体氧化物燃料电池(SOFC)模式时,单电池800℃时的最大输出功率密度可以达到170 W cm^(-2);而在固体氧化物电解池(SOEC)模式下,800℃、1.3 V时电解池的电解电流密度达到-0.256 A cm^(-2).在SOFC-SOEC循环测试过程中,RSOC中CO-CO_(2)相互转化过程经历了“活化-稳定-衰退”三个明显阶段.幸运的是,性能衰退的燃料电极可通过“原位氧化-还原”处理实现性能再生,有效提升该电池的使用寿命.研究结果表明,原位脱溶形成的FeRu@PSFRM材料是一种极具应用潜力的燃料电极候选材料,以期实现高效稳定的CO-CO_(2)相互转化.

Accelerated life-time test of MEA durability under vehicle operating conditions in PEM fuel cell

In this paper, a novel accelerated test method was proposed to analyze the durability of MEA, considering the actual operation of the fuel cell vehicle. The proposed method includes 7 working conditions： open circuit voltage （OCV）, idling, rated output, overload, idling-rated cycle, idling-overload cycle, and OCV-idling cycle. The experimental results indicate that the proposed method can effectively destroy the MEA in a short time （165 h）. Moreover, the degradation mechanism of MEA was analyzed by measuring the polarization curve, CV, SEM and TEM. This paper may provide a new research direction for improving the durability of fuel cell.

Test sequencing problem arising at the design stage for reducing life cycle cost

Previous test sequencing algorithms only consider the execution cost of a test at the application stage. Due to the fact that the placement cost of some tests at the design stage is considerably high compared with the execution cost, the sequential diagnosis strategy obtained by previous methods is actually not optimal from the view of life cycle. In this paper, the test sequencing problem based on life cycle cost is presented. It is formulated as an optimization problem, which is non-deterministic polynomial-time hard （NP-hard）. An algorithm and a strategy to improve its computational efficiency are proposed. The formulation and algorithms are tested on various simulated systems and comparisons are made with the extant test sequencing methods. Application on a pump rotational speed control （PRSC） system of a spacecraft is studied in detail. Both the simulation results and the real-world case application results suggest that the solution proposed in this paper can significantly reduce the life cycle cost of a sequential fault diagnosis strategy.

Mechanical Characteristics and Mechanism of Granite Subjected to Coupling Effect of Acidic Corrosion and Freeze-Thaw Cycles

The typical climatic and environmental conditions in Central Asia are major natural factors causing local rock masses to face considerable risks of damage due to constant freeze-thaw cycles. In addition, these are exacerbated by the dense acidic environments in certain industrialized areas, such as Northern Sinkiang, China. To provide local engineering design with workable solutions, it is crucial to analyze the mechanical performance of rock masses and its mechanisms under the coupling action of corrosive acid and freeze-thaw cycles. In this study, granite samples from the northern Tien Shan Mountains near Urumchi, Xinjiang Province, as well as two kinds of sandstone samples for comparison, were subjected to different soaking conditions, including nitric acid soaking at various pH values. One or both of the freeze-thaw cycle tests and uniaxial compression test were then executed. Speculations regarding the mechanism of the performance of granite rock masses under the action of corrosive acid and freeze-thaw cycles were developed based on the results of these tests. X-ray diffraction and scanning electron microscopy were implemented to demonstrate the feasibility of the speculated mechanism. In this paper, the identification of the white crumb-like substance as SiO_(2) gel were confirmed.

Real drive cycles analysis by ordered power methodology applied to fuel consumption,C0_(2),NO_(x) and PM emissions estimation

In this work three fuel consumption and exhaust emission models,ADVISOR,VT-MICRO and the European Environmental Agency Emission factors,have been used to obtain fuel consumption(FC)and exhaust emissions.These models have been used at micro-scale,using the two signal treatment methods presented.The manuscript presents:1)a methodology to collect data in real urban driving cycles,2)an estimation of FC and tailpipe emissions using some available models in literature,and 3)a novel analysis of the results based on delivered wheel power.The results include Fuel Consumption(FC),CO_(2),NO_(x) and PM_(10) emissions,which are derived from the three simulators.In the first part of the paper we present a new procedure for incomplete drive cycle data treatment,which is necessary for real drive cycle acquisition in high density cities.Then the models are used to obtain second by second FC and exhaust emissions.Finally,a new methodology named Cycle Analysis by Ordered Power(CAbOP)is presented and used to compare the results.This method consists in the re-ordering of time dependant data,considering the wheel mechanical power domain instead of the standard time domain.This new strategy allows the 5 situations in drive cycles to be clearly visualized:hard breaking zone,slowdowns,idle or stop zone,sustained speed zone and acceleration zone.The complete methodology is applied in two real drive cycles surveyed in Barcelona(Spain)and the results are compared with a standardized WLTC urban cycle.