As two representative materials of wide-bandgap semiconductors, gallium nitride (GaN) currently thrives in the fast charging sector of consumer electronics, while silicon carbide (SiC) is gradually gaining ground in the application scenarios of new energy vehicles. Simultaneously, both are expanding into broader application boundaries. The strong emergence of AI has created new incremental markets for silicon carbide and gallium nitride.

Against this backdrop, innovative products such as Infineon’s CoolSiC™ MOSFET 400V series and Navitas’ new 4.5kW server power supply solutions have recently been launched, driving the increasing popularity of silicon carbide/gallium nitride in AI server power supplies (PSU).

Silicon Carbide/Gallium Nitride: The Breakthrough for PSU Upgrades

In recent years, the hot application of generative AI and the explosive growth of AI chip computing power have led to a surge in global data center electricity consumption. To address the high energy consumption crisis brought about by AI, upgrading data center PSUs has become a critical breakthrough.

Currently, PSUs for global AI and hyperscale computing data centers come in three form factors: CRPS185, CRPS265, and OCP of the Open Compute Project. The heights and widths of these power supplies are the same, differing only in length. Each CRPS185 power supply has fixed dimensions of 185mm x 73.5mm x 40mm. Thus, given that the physical size cannot change, increasing power demands from AI servers necessitate improvements in power density.

Power density enhancements can be achieved by increasing switching frequency. Since silicon-based products have reached their physical performance limits, the high switching frequency characteristics of GaN devices make them more suitable for high-density CRPS applications. In contrast, SiC devices, compared to silicon-based products, can operate at higher temperatures and voltages, achieving more efficient power conversion and reducing energy loss.

In practical applications, Navitas has significantly improved power density and efficiency through a reference design for CRPS server power supplies that combines SiC power devices and GaN power chips. In July this year, Navitas released an innovative CRPS185 4.5kW AI data center server power supply solution based on its GaNSafe™ high-power GaN power chips and the third-generation fast SiC power devices from GeneSiC™, reportedly achieving a leading power density of 137W/in³ and efficiency of over 97% in the AI data center PSU industry.

The Battle for AI Server Power Supplies Among Leading Silicon Carbide/Gallium Nitride Power Device Manufacturers

A competition in AI server power supplies among SiC/GaN power device manufacturers is already underway. Apart from Navitas, players such as Infineon, ON Semiconductor, EPC, Texas Instruments, GaNext, Corenergy, and Danxitech have entered the fray.

Infineon

In June of this year, Infineon launched a new CoolSiC™ MOSFET 400V series specially developed for AC/DC stages of AI servers. This new series has lower conduction and switching losses compared to existing 650V SiC and Si MOSFETs, increasing the power density of AI server power supplies to over 100W/in³ and achieving an efficiency of 99.5%, which is 0.3 percentage points higher than solutions using 650V SiC MOSFETs.

For the 54V output platform of AI servers, Infineon has developed a 3.3kW PSU dedicated demo board, utilizing Infineon’s CoolGaN™, CoolSiC™, and CoolMOS™ designs to achieve a benchmark overall efficiency of 97.5% and a power density of 96W/in³, meeting the high-power demands of data center PSUs.

At the PCIM Asia 2024 exhibition, an Infineon spokesperson emphasized that reducing data center energy consumption is a pressing need for AI industry development and a primary focus for Infineon. Infineon’s new generation of SiC MOSFET trench gate technology features lower on-resistance, higher switching efficiency, and better reliability, offering significant performance improvements to meet the needs of AI server power supplies.

ON Semiconductor

In response to the “three highs” challenge of PSU output power, conversion efficiency, and power density, ON Semiconductor has launched the latest generation of T10 PowerTrench® series and EliteSiC 650V MOSFET combination, providing a comprehensive solution for data center applications. This solution offers higher efficiency and better thermal performance in a smaller package size.

Among these products, the EliteSiC 650V SiC M3S MOSFET is designed to address data center efficiency challenges, meeting the Open Rack V3 (ORV3) PSU’s peak efficiency requirement of up to 97.5%. The T10 PowerTrench® series enhances thermal performance through optimized packaging technology, addressing the need for high power conversion efficiency and miniaturization in data centers.

EPC

At the PCIM exhibition, EPC showcased samples of humanoid robots using GaN and an autonomous mini-vehicle incorporating EPC’s GaN power devices in its onboard LiDAR components.

In addition to scenarios like humanoid robots and LiDAR, AI data center PSUs are also a key focus area for EPC. In communications with TrendForce Compound Semiconductor, Zhang Shengke, Vice President of EPC’s Reliability Division, stated that EPC’s low-voltage GaN devices can meet all 48V-to-12V server power converter component needs.

TI

As early as 2021, TI had reached a collaboration with server power supply provider Delta to develop efficient, high-power enterprise PSUs for data centers based on TI’s GaN technology and C2000™ MCU real-time control solutions.

TI has invested ten years into GaN technology and C2000™ MCU real-time control solutions. Through collaboration with Delta, TI can utilize innovative semiconductor manufacturing processes to produce silicon-based GaN and integrated circuits, helping companies like Delta create differentiated applications and power data centers worldwide more efficiently.

To lead the industry’s development, both Navitas and Infineon announced their AI data center power supply technology roadmaps, demonstrating their commitment to continuously strengthen their presence in this field.

To meet the exponential power demand increase of AI data centers, Navitas is continuously developing new server power supply platforms, aiming to rapidly elevate power levels from 3kW to 10kW, with a launch expected in Q4 2024.

In addition to its existing 3kW and 3.3kW PSUs, Infineon will soon launch new 8kW and 12kW PSUs to further enhance AI data center efficiency. With the 12kW reference board, Infineon is poised to release the world’s first AI data center PSU to achieve this performance level.

On the domestic front, GaNext has partnered with prestigious universities to jointly develop and mass-produce the industry’s first 3.5kW CRPS fanless server power supply, achieving a high efficiency of 97.6% through two-phase interleaved totem-pole PFC and LLC, with a power density reaching 73.6W/Inch³. Several relevant products from Nengsi Technology have been sampled by leading domestic enterprises and have successfully completed the related reliability tests. Danxitech’s related products have been sampled to leading domestic companies and have completed reliability tests. Corenergy ‘s 1200V GaN products have been sampled by a known server power supplier and are undergoing reliability evaluation. Various major manufacturers are jointly advancing the industrialization of GaN in AI data center PSU applications.

Summing up, power density and efficiency in AI server power supplies continue to improve, focusing on two primary performance indicators for SiC/GaN power device manufacturers. This trend is likely to spur the production of various high-performance products, attracting more SiC/GaN players to enter the market.

Conclusion

The data center power supply sector has become a key focus of leading silicon carbide/gallium nitride manufacturers in recent years. Some manufacturers’ SiC/GaN products have already made progress in the data center power supply market, with the strong rise of AI further driving the development of this market.

As AI technologies evolve and computational power demand continues to grow, the energy efficiency and power density requirements of data centers will become increasingly stringent, imposing higher performance demands on SiC/GaN power device products from various manufacturers.

The continuous development of the SiC and GaN industry, coupled with the thriving AI ecosystem, will result in more intersections between SiC, GaN, and AI. The competition for AI server power supplies among major manufacturers will become increasingly intense.

In recent developments, an industry source revealed that Coherent, a leading chip material supplier in the U.S. automotive industry, has piqued the interest of four major Japanese corporate groups with regards to its silicon carbide (SiC) business, with a transaction amount potentially reaching $5 billion.

The four Japanese companies involved are DENSO, Hitachi, Mitsubishi Electric, and Sumitomo Electric, and discussions have been underway regarding the acquisition of minority stakes in Coherent’s SiC business.

Coherent had previously stated its intention to invest $1 billion over the next decade to expand the production of SiC wafers. Compared to traditional silicon chips, SiC wafers contribute to improved electric vehicle range. If this investment materializes, it would significantly ease the financial burden on the company. However, no concrete agreements have been reached at this stage.

Data indicates that Coherent is one of the few companies globally with complete and vertically integrated SiC manufacturing capabilities. It can produce SiC wafers and epitaxy materials, extending all the way to power devices. Furthermore, Coherent’s SiC materials are known for their exceptional quality, making it nearly the only supplier capable of transitioning from the current standard wafer diameter of 150 millimeters to 200 millimeters successfully. The production of larger diameter wafers can substantially reduce device costs. Additionally, Coherent’s SiC power devices demonstrate excellent heat resistance and conductivity.

Competition and Collaboration in the Japanese SiC Industry

According to TrendForce’s latest analysis, as collaborations between companies like Infineon and ON Semiconductor with automotive and energy sector stakeholders become more apparent, the overall SiC power device market is projected to reach $2.28 billion in 2023, growing at an annual rate of 41.4%.

Meanwhile, buoyed by robust demand in downstream application markets, TrendForce anticipates that the SiC power device market could reach $5.33 billion by 2026, with its primary applications continuing to center around electric vehicles and renewable energy.

In recent years, the new energy vehicle industry has been thriving, and Si power devices have gradually fallen short of meeting the demands of new energy vehicles. SiC, as its alternative, has shown remarkable performance in applications, making it highly sought after in the market. The SiC power device market still has considerable room for growth, prompting both automotive and SiC companies to invest in SiC power device production or enhancements.

Japan, being a leader in semiconductor power device manufacturing and production, has numerous companies actively expanding to broaden their market reach.

On October 4th last year, Nikkan reported that Hitachi Power Semiconductor Device would invest several billion yen, aiming to triple its SiC power semiconductor production capacity by fiscal year 2026.

On July 12th this year, ROHM announced its acquisition of the former Solar Frontier factory in Kunitomi, Miyazaki, to expand its SiC power semiconductor production capacity. The acquisition is set to conclude in October 2023 and is planned to become the company’s main factory, primarily producing SiC power semiconductors. It is expected to increase its silicon carbide capacity to 35 times that of the fiscal year 2021 by 2030.

With these competitive and cooperative scenarios unfolding, it’s evident that neither automotive nor SiC companies are holding back in their pursuit of SiC power device production or improvements.

In July this year, Renesas Electronics signed a 10-year agreement and paid $2 billion in advance to Wolfspeed for the supply of 150mm bare and epitaxial SiC wafers. Renesas Electronics also reached an agreement with Mitsubishi Electric, with Mitsubishi investing 260 billion yen in technology and expansion, including the construction of a new SiC factory in Japan.

As a technological leader in producing SiC substrates, epitaxy, and power devices, Coherent is not to be overlooked by these major corporations.

On May 26th this year, Coherent and Mitsubishi Electric announced that they had signed a MOU and reached a project collaboration agreement to jointly scale up the mass production of SiC power electronic products on a 200mm technology platform.

Mitsubishi Electric announced that it would invest approximately 260 billion yen over a five-year period ending in March 2026, with approximately 100 billion yen dedicated to constructing a new SiC power device factory based on a 200mm technology platform and strengthening related production facilities. According to the MOU, Coherent will develop 200mm n-type 4H SiC substrates for Mitsubishi Electric’s future SiC power devices to be produced at the new factory.

In the future, Mitsubishi Electric aims to produce large quantities of silicon carbide chips using Coherent’s 200mm wafer technology in the Japanese market.

In the 2023 fiscal third-quarter earnings conference call, Mary Jane Raymond, the Chief Financial Officer of Coherent Inc., mentioned that the revenue composition of the company’s four main markets is as follows, based on regional distribution: North America accounts for 53%, Europe accounts for 20%, Japan and Korea account for 14%, China accounts for 11%, and 3% goes to other regions worldwide.

For Coherent, capturing 14% of the sales in the Japanese and Korean markets is highly significant. If Coherent continues its collaboration with Japanese partners, it is highly probable that the production capacity of SiC power devices in Japanese-related companies will be increased. Additionally, this will allow Coherent to further expand its influence and presence in Japan.

(Photo credit: Coherent)

Last week, major power semiconductor manufacturer Infineon announced plans to invest up to 5 billion euros over the next five years to construct the world’s largest 8-inch SiC power wafer factory in Kulim, Malaysia. This expansion will raise the total investment in the Kulim plant from 2 billion euros to 7 billion euros.

Interestingly, in February of this year, Wolfspeed announced its own plans to build what is touted as the world’s largest 8-inch SiC factory in the Saarland region of Germany. Infineon’s significant investment in the Malaysian 8-inch SiC factory sets the stage for potential competition with Wolfspeed, sparking an impending battle for Silicon Carbide production capacity.

In fact, driven by the rapid growth of industries like electric vehicles, the space for SiC power devices is expanding, attracting both Chinese companies and international enterprises to ramp up production.

According to statistics from TrendForce, aside from Wolfspeed, the first half of this year saw numerous companies, including STMicroelectronics, Mitsubishi Electric, Rohm, Soitec, and ON Semiconductor, expanding their production capacities. STMicroelectronics, for instance, announced a $4 billion investment in January to expand 12-inch wafer production. In June, they partnered with San’an Optoelectronics to establish a joint venture for 8-inch SiC device manufacturing, with an estimated total investment of around $3.2 billion.

On the Chinese front, there have been seven expansion projects related to Silicon Carbide. CRRC is investing 11.12 billion yuan to establish a project for the industrialization of medium and low-voltage power devices. YASC is also planning to construct a Compound Semiconductor power device production project, encompassing epitaxial growth, wafer manufacturing, packaging, and testing lines. Upon completion, the facility will have an annual production capacity of 360,000 6-inch SiC wafers and 61 million power device modules.

Additionally, BYD plans to invest 200 million yuan to establish a SiC epitaxial trial production and mass production project at its automotive production base in Shenzhen. The expansion will add 6,000 SiC epitaxial wafers per year, bringing the total capacity to 18,000 wafers per year.

(Photo credit: Tesla)

Not only did automotive market take a downward turn starting in 2018, but the severe impact of the COVID-19 pandemic in 2020 also led to noticeably insufficient procurement activities from major automotive module suppliers, according to TrendForce’s latest investigations. However, as the automotive market is currently set to make a recovery, TrendForce expects yearly vehicle sales to increase from 77 million units in 2020 to 84 million units in 2021.

At the same time, the rising popularity of autonomous, connected, and electric vehicles is likely to lead to a massive consumption of various semiconductor components. Even so, since most manufacturers in the automotive supply chain currently possess a relatively low inventory, due to their sluggish procurement activities last year in light of weak demand, the discrepancies in the inventory levels of various automotive components, along with the resultant manufacturing bottleneck, have substantially impaired automakers’ capacity utilization rates and, subsequently, vehicle shipments.

The recent shortage situation in the IC supply chain has gradually extended from consumer electronics and ICT products to the industrial and automotive markets. In the past, manufacturers in the automotive semiconductor industry were primarily based on IDM or fab-lite business models, such as NXP, Infineon, STMicroelectronics, Renesas, ON Semiconductor, Broadcom, TI, etc. As automotive ICs generally operate in wide temperature and high voltage circumstances, have relatively long product lifecycle, and place a heavy demand on reliability as well as longevity support, it is more difficult for the industry to alternatively transition its production lines and supply chains elsewhere.

Automotive semiconductor remains in shortage as production capacities remain fully loaded across the global foundry industry

Nevertheless, given the current shortage of production capacities across the foundry industry, wafer capacities allocated to automotive semiconductor components have been noticeably crowded out by other products. Some of these examples include automotive MCU and CIS manufactured in 12-inch fabs, as well as MEMS, Discrete, PMIC, and DDI products manufactured in 8-inch fabs. TrendForce indicates that automotive semiconductor products manufactured at the 28nm, 45nm, and 65nm nodes in 12-inch fabs are suffering the most severe shortage at the moment, while production capacities at 0.18µm and above nodes in 8-inch fabs have also been in long queue by other products.

As in-house IDM fabrications have relatively high CAPEX, R&D expense, and operating overhead, automotive IC vendors have in recent years outsourced some of their products to TSMC, GlobalFoundries, UMC, Samsung, VIS, Win Semiconductor and so on. In particular, TSMC specifically indicated during its 4Q20 earnings conference that wafer starts for automotive semiconductors reached rock bottom in 3Q20, while additional orders began arriving in 4Q20. As such, the company is currently considering allocating some of its production capacities from logic ICs to specialty foundry, in order to meet sudden demand from its long-term customer relationship.

For more information on reports and market data from TrendForce’s Department of Semiconductor Research, please click here, or email Ms. Latte Chung from the Sales Department at lattechung@trendforce.com