Innovative materials/manufacturing for a prototype 600-1000VDC DC/DC Converter for Shipboard Radar

Future Navy Active Electronically Steered Array (AESA) radar systems demand higher peak and average power levels requiring development of high power density, isolated DC/DC converters for pulsed current loads. The Navy requires an advanced DC/DC converter design compatible with Transmit/Receive (T/R) Modules utilized in Navy AESA radar systems and compatible with shipboard power requirements. The power systems within AESA radar systems consume significant power, space and thermal management resources. During Phase I, we will identify, model, and develop an innovative converter design incorporating materials, technologies, and manufacturing processes that significantly improve performance and reliability. CME will evaluate components, perform simulations, develop a detailed design, and conduct proof of concept experiments. Our proposal provides specific design approach to the development of the converter to be initiated during Phase I. The objective is a high efficiency, high power density, low noise, 2.5 kW DC/DC converter for insertion into developing Air and Missile Defense Radar (AMDR) systems. Based on the Phase I design and any improvements in materials, technologies, and manufacturing processes developed, we will be ready to build and test a prototype DC/DC converter to support a Navy transition.