Loss-Driven Design Methodology for MHz-Class GaN QSW Buck Converters with a PCB Air-Core Inductor in SWaP-Constrained Aerospace Applications

Aerospace power systems, including satellites in low earth orbit (LEO) and geostationary earth orbit (GEO), face stringent thermal constraints to minimize size, weight, and power (SWaP). Gallium nitride (GaN) devices offer superior radiation hardness—critical for the harsh space environment—and MHz-level switching capabilities. This high-frequency operation minimizes passive components, particularly magnetics, thereby reducing the overall volume. However, above 10 MHz, magnetic cores become impractical due to material limitations. To address these issues, this article proposes a design methodology for a GaN-based quasi-square-wave (QSW) buck converter integrated with a PCB air-core inductor. First, the impact of the switching frequency and dead time on the zero-voltage switching (ZVS) condition is elaborated. Then, a power loss model accounting for various loss mechanisms is presented. To overcome high GaN body diode reverse conduction loss, an auxiliary diode is employed. Based on the model, a design procedure is developed to optimize the inductor for 10 MHz operation while maximizing efficiency. To validate the design, a 28 V/12 V, 18 W prototype was built and tested. Experimental results demonstrate a peak efficiency of 86.5% at 10 MHz. The auxiliary diode improves efficiency by 4%, verifying reverse conduction loss mitigation. Thermal analysis confirms a full-load case temperature of 62.2 ${}^{\circ }$C, providing a 47.8 ${}^{\circ }$C safety margin compliant with aerospace derating standards. These findings validate the solution for high-frequency, space-constrained aerospace applications.