Next Generation Power Electronics Manufacturing Innovation Institute February 27, 2014 Research Retreat Dennis Kekas Interim Executive Director, Next Generation Power Electronics Manufacturing Innovation Institute North Carolina State University © 2014

Loss of U.S. Manufacturing Employment $25,634,942 (18%) State Appropriated Funds Challenge: Loss of U.S. Manufacturing Employment Employees (thousands) Year Source: data.bls.gov, Current Employment Statistics Survey

Next Generation Power Electronics Manufacturing Innovation Institute Vision: Wide bandgap technology for a more energy efficient world Mission: Develop a manufacturing-focused innovation ecosystem to reduce cost, improve performance and reliability, and enable U.S. industry dominance in WBG semiconductor devices and systems to create jobs. As we look at US and world today, there are two simultaneous and seemingly intractable grand challenges: The Opportunity We are grateful to the DOE for its leadership and seizing the opportunity to launch the WBG Institute program.

Applications

Operate above 300 oC compared to 150 oC for Silicon-based devices Reduce losses during DC-to-AC electricity conversion by 90% Handle 10 times higher voltages Produce bulbs with 10 times more light that last 30 times longer … * WBG materials (specifically silicon carbide) may reduce electricity losses during vehicle battery recharging by nearly two-thirds, making it cheaper to recharge electric and plug-in hybrid vehicles. In hybrid and electric vehicles, a second cooling system is needed to cool the power electronics. The higher operating temp of silicon carbide could allow the size of the cooling system to be reduced by 60%, or even eliminated altogether, significantly reducing the overall size of the car engine. * Reduction in losses during DC-to-AC electricity conversion will help integrate renewable sources of electricity into the power grid. Inverters are needed to convert the DC electricity produced by solar panels and wind turbines into the AC electricity that flows to our receptacles. Replacing current inverters with SiC devices could cut losses by 90%. * Powering motor systems consumes 69% of the electricity used in U.S. manufacturing. WBG materials will enable higher efficiency motor drive systems for pumps, fans, compressors, and HVAC systems. saving $250B by 2030

Founding Partners RD&D Wafer Suppliers Design House /Device Manufacture Device and Package Foundry Power Electronics Companies RD&D North Carolina State University © 2014

MARKET DEMAND MANUFACTURING PROCESS PRODUCTS TALENT Research, Development & Demonstration Comprehensive Education and Workforce Development Program MARKET DEMAND MANUFACTURING PROCESS PRODUCTS TALENT Thriving Power Electronics Industry Ecosystem Commercial Product Acceleration Production & Packaging Foundries

Comprehensive Education and Workforce Development Program TALENT: Comprehensive Education and Workforce Development Program $25,634,942 (18%) State Appropriated Funds Summer Institute Training for working professionals Training community college and high school teachers Undergraduate Research Program WBG Professional Science Masters Online WBG University MEP provided training

Approach To Innovation OEMs Market Demand and Feedback Wafer Suppliers Device Design House Approach To Innovation Wafer Fabs Our approach Packaging Fabs

Vehicle Traction Inverter MARKET DEMAND: Commercial Product Acceleration End Products Devices Power 20kW 75kW 200kW RFMD 600V, GaN HFET Delphi Vehicle Traction Inverter 600V 1200V, GaN Vertical Tr. Avogy Toshiba PV Inverter 1200V Monolith Semi. & X-Fab 1200V, SiC JBS, MOSFET Toshiba PV Inverter Toshiba PV Inverter John Deere Heavy Duty EV Inverter Monolith Semi. & X-Fab 1700V 1700V, SiC JBS, MOSFET Vacon Medium Voltage Drive 4.5kV 4500V SiC JBS, MOSFET USCi Toshiba MVD 10kV GridBridge Grid Energy Router 10kV, SiC JBS, MOSFET CREE 15kV Voltage

Reach Parity with Silicon Low Voltage Devices (600V to 1700V) Medium Voltage (3300V to 6500V) 3 years 5 years High Voltage Devices (> 10kV) 10 years Currently 10X Currently 10X Don’t Exist Achieve last 50% cost reduction via Power Electronics Innovation TARGET: WBG Costs Reach Parity with Silicon Cost Parity 1.5X

Wide Bandgap Service Centers and Shared RD&D Facilities Increase reliability Improve performance Reduce cost Establish standard testing benchmarks ❶❷❻ Long-term reliability test ❶❷❹❺ Identify physics of failure mechanism ❹❺❻ Develop ruggedness by process/device ❸❹❻ Reliability Devices to exploit WBG benefits ❸❹❻ Advanced package development ❶❷❺ Application aligned device choice ❶❷❸ Develop WBG exclusive application ❶❷ Performance Improve materials for predictive output ❹❺❻ Larger volume inviting many customers ❶❷❺ Silicon compatible manufacturability ❸❹❻ Novel device, package development ❸❺❻ Cost 1 High Power Electronics 2 Power Supply 3 Device Design 4 Device Failure Analysis 5 Power Module Failure Analysis & Reliability 6 Device Fabrication & Characterization WBG Service Centers WBG Service Centers 1 WBG High Power Electronics 2 WBG Power Supply 3 WBG Device Design 4 WBG Device Failure Analysis 5 WBG Power Module Failure Analysis & Reliability 6 WBG Device Fabrication & Characterization

RD&D Thrust Areas IP Generation & Technology Transfer Critical GaN Research - Umesh Mishra, Lead - GaN Ron Scaling - Stability and Reliability - Normally-off mode Critical SiC Research - Jay Baliga, Lead - MOS interface quality - Bipolar degradation Power Electronics - Fred Lee, Lead - High density converters - Low cost PV inverters - High temperature EV inverters Packaging - Doug Hopkins, Lead - High temperature packaging - Low Rth - Low parasitic inductance

NC State Expertise North Carolina State University © 2014

Existing Infrastructure at NC State NC State’s Centennial Campus NCSU Nanofabrication Facility NSF FREEDM NNF, AIF Analytical Instrumentation Facility

Building Industry Partnerships NC State Competency: Building Industry Partnerships Centers & Institutes draw about 180 partners, including some of the top names in industry. North Carolina State University © 2014

Transforming Economies Dennis Kekas research.ncsu.edu/power