Project
Enabling Technology and Grid-Tied Testbed for Efficient, Flexible Distribution Transformers
Developing better transformer materials, sensors, and testing infrastructure to improve US grid efficiency and supply chains
Just starting
Project
Developing better transformer materials, sensors, and testing infrastructure to improve US grid efficiency and supply chains
Just starting
Distribution transformers waste almost 1% of all power on the grid, and the US doesn't make enough of the newer, more efficient ones fast enough to meet demand. One goal is to design and test new magnetic alloys that lose less energy than today's materials, while also being easier to manufacture in the US instead of relying on imports. Other parts of the project are building smarter transformers with sensors that can warn utilities before they fail, and exploring newer electronic transformer designs.
The project addresses distribution transformer efficiency, reliability, and domestic supply chain resilience. One main goal focuses on amorphous and nanocrystalline soft magnetic alloy development to meet DOE efficiency standards, allowing for a shift from grain-oriented electrical steels towards more amorphous materials. Alloy compositions are being tuned computationally using glass forming ability, magnetostriction, and saturation magnetization properties to identify candidates that balance magnetic performance and manufacturability. Small scale casting is performed using a mini-arc melter and a melt spinner, magnetic saturation is tested using a VSM, and magnetostriction tested using a custom setup. Glass forming ability is modeled through ThermoCalc predictions. Additional goals include scaling up the designed alloys with CorePowers large scale caster and advancing solid-state transformer (SST) architectures with embedded energy storage and real-time power-flow control.