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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Influence of elongation and triangularity on plasma response to resonant magnetic perturbations

Abstract Systematic toroidal modeling of the plasma response to the n = 1–4 ( n is the toroidal mode number) resonant magnetic perturbation (RMP) field is carried out in order to understand the plasma-shaping effect on controlling the type-I edge-localized modes (ELMs) in tokamak experiments. Considered are large variations of the plasma elongation and triangularity at a fixed edge safety factor q a , for limiter plasmas with both single-null (SN) and double-null (DN) divertor-like boundary shapes. Numerical results assuming conformal 3D RMP coils show that (i) the optimum coil phasing between the upper and lower rows for ELM control becomes increasingly sensitive to the plasma elongation with higher- n toroidal spectra, (ii) the optimum coil phasing is however essentially independent of the plasma triangularity for all n = 1–4 RMP fields, (iii) with the same coil current and the optimum coil phasing, high elongation generally favors ELM control but it may be more challenging for plasmas with intermediate elongation and with lower- n ( n = 1–2) RMPs, and (iv) higher triangularity is generally always better for ELM control with all n = 1–4 fields for both DN and SN divertor-like plasma boundary shapes.

Physics↗
NASA NTRS1997

Robotic multimodality stereotactic brain tissue identification: work in progress

Real-time identification of tissue would improve procedures such as stereotactic brain biopsy (SBX), functional and implantation neurosurgery, and brain tumor excision. To standard SBX equipment has been added: (1) computer-controlled stepper motors to drive the biopsy needle/probe precisely; (2) multiple microprobes to track tissue density, detect blood vessels and changes in blood flow, and distinguish the various tissues being penetrated; (3) neural net learning programs to allow real-time comparisons of current data with a normative data bank; (4) three-dimensional graphic displays to follow the probe as it traverses brain tissue. The probe can differentiate substances such as pig brain, differing consistencies of the 'brain-like' foodstuff tofu, and gels made to simulate brain, as well as detect blood vessels imbedded in these substances. Multimodality probes should improve the safety, efficacy, and diagnostic accuracy of SBX and other neurosurgical procedures.

Brain/anatomy & histology/surgery↗
NASA NTRSDate not supplied

Current Status and Future Plans for Electric Motors and Drives at NASA

Current Status and Future Plans for Electric Motors and Drives at NASA: Our work advances propulsion for aircraft while reducing energy consumption, noise, emissions and the cost of air travel. We are committed to investigating the use of alternative energy sources and improving the safety and expediency of flight. Electrified Aircraft Propulsion (EAP) is the use of propulsors (propellers or fans) driven by electric motors to propel aircraft ranging from air taxis to subsonic transports. NASA is developing technology, aircraft concepts, test aircraft, and ground test facilities to turn this idea from science fiction to reality. Specifically, motors and/or generators (Electric machines) are needed on all electrified aircraft. And NASA is sponsoring or performing work to achieve power densities 2-3 times the state of the art for machines in the MW or larger class. Three major machine types are being developed: permanent magnet, induction, and wound field. Power converters are also an essential component in most EAP aircraft concepts, as they are used to convert from ac to dc power, or vice versa. Silicon carbide and gallium nitride convertors are being developed with conventional cooling as well as a cryogenically cooled converter. Future plans include demonstrating integrated flight-ready systems in both ground and flight tests; collaborating with and leveraging ARPA-E EAP programs; and supporting FAA standards development for market acceptance and safety.

Powertrain↗
NASA NTRSDate not supplied

Current Status and Future Plans for Electric Motors and Drives at NASA

Our work advances propulsion for aircraft while reducing energy consumption, noise, emissions and the cost of air travel. We are committed to investigating the use of alternative energy sources and improving the safety and expediency of flight. Electrified Aircraft Propulsion (EAP) is the use of propulsors (propellers or fans) driven by electric motors to propel aircraft ranging from air taxis to subsonic transports. NASA is developing technology, aircraft concepts, test aircraft, and ground test facilities to turn this idea from science fiction to- reality. Specifically, motors and/or generators (Electric machines) are needed on all electrified aircraft. And NASA is sponsoring or performing work to achieve power densities 2-3 times the state of the art for machines in the MW or larger class. Three major machine types are being developed: permanent magnet, induction, and wound field. Power converters are also an essential component in most EAP aircraft concepts, as they are used to convert from ac to dc power, or vice versa. Silicon carbide and gallium nitride convertors are being developed with conventional cooling as well as a cryogenically cooled converter. Future plans include demonstrating integrated flight-ready systems in both ground and flight tests; collaborating with and leveraging ARPA-E EAP programs; and supporting FAA standards development for market acceptance and safety.

Aircraft↗
DOE OSTI2022

Ultra High-Temperature Magnetic Bearing System for s-CO 2 Turbines/Expanders. Phase II Final Report

The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Rapid RASER MRI

Conventional Magnetic Resonance Imaging (MRI) relies on high-power Radio-Frequency (RF) pulses to excite nuclear spins and in turn generate NMR signals. These pulses require large high-power RF-amplifiers and cause heat deposition in the tissue, which must be minimized for safety, presenting a growing problem when moving toward ever-higher field MRI. An alternative to RF-pulse excitation is self-excitation of nuclear spins using Radiofrequency Amplification by Stimulated Emission of Radiation (RASER), where the nuclear spins undergo spontaneous transition, without RF excitation, from an over-populated state to a ground state. Here, the feasibility of recording rapid proton RASER MRI images of pyrazine at low concentration (120 mM) with large matrix (128x128 pixels) in as little as 78 ms is demonstrated at 500 MHz (11.7 T). We also recorded a time-series of images using a single bolus hyperpolarized pyrazine highlighting the feasibility of dynamic tracking. Here, the demonstrated approach allows recording MRI scans without transmit-receive electronics of the MRI scanner, which is highly desirable for portable MRI as well as the emerging field of hyperpolarized MRI using, e.g., HP protons, 129 Xe gas or HP 13 C labeled biomolecules as molecular tracers and imaging agents.

MRI↗
DOE OSTI2022

General overview of multiphysics modeling and simulation at CEA/DES/IRESNE supporting safety, operating and development of nuclear reactors and facilities

This paper presents a general overview of the innovative multiphysics research/development activities carried on by the CEA/DES/IRESNE institute. Eight main different multiphysics fields addressed by IRESNE have been listed (among others: fuel fabrication, behavior of fuels, of reactors, of corium, radionuclide transfer to environment,...) in relation with the involved coupled physics: neutron transport, fluid mechanics, electro-magnetism, heat transfer, solid mechanics and (physico-)chemistry. The major mission of IRESNE institute is to study current and future nuclear systems integrated into a low carbon energy system. To fulfill this mission, IRESNE's activities rely on the development and the implementation of multiphysics modeling, advanced coupling scheme, data transfer techniques and dedicated multiphysics experimentations. Indeed, such multiphysics simulation approach of nuclear systems is today required to deal with the complex intrinsic features of studied phenomena. This approach aims at taking into account physical phenomena interactions, at each interest modeling scale, in order to reach an accurate and predictive behavior representation of a system component or of the whole system. The final objective is to contribute to the development of digital reactor, core and fuel at CEA, by progressing on applied mathematics, high-performance computing and physical mechanism understanding.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Laboratory Study of the Torus Instability Threshold in Solar-relevant, Line-tied Magnetic Flux Ropes

Coronal mass ejections (CMEs) occur when long-lived magnetic flux ropes (MFRs) anchored to the solar surface destabilize and erupt away from the Sun. This destabilization is often described in terms of an ideal magnetohydrodynamic instability called the torus instability. It occurs when the external magnetic field decreases sufficiently fast such that its decay index, ${n}_{}=-z\,\partial (\mathrm{ln}{B}_{})/\partial z$, is larger than a critical value, $n\gt {n}_{\mathrm{cr}}^{}$, where ${n}_{\mathrm{cr}}^{}=1.5$ for a full, large aspect ratio torus. However, when this is applied to solar MFRs, a range of conflicting values for ${n}_{\mathrm{cr}}^{}$ is found in the literature. To investigate this discrepancy, we have conducted laboratory experiments on arched, line-tied flux ropes and applied a theoretical model of the torus instability. Our model describes an MFR as a partial torus with foot points anchored in a conducting surface and numerically calculates various magnetic forces on it. This calculation yields better predictions of ${n}_{\mathrm{cr}}^{}$ that take into account the specific parameters of the MFR. Here, we describe a systematic methodology to properly translate laboratory results to their solar counterparts, provided that the MFRs have a sufficiently small edge safety factor or, equivalently, a large enough twist. After this translation, our model predicts that ${n}_{\mathrm{cr}}^{}$ in solar conditions falls near ${n}_{\mathrm{cr}}^{\mathrm{solar}}\sim 0.9$ and within a larger range of ${n}_{\mathrm{cr}}^{\mathrm{solar}}\sim (0.7,1.2)$, depending on the parameters. The methodology of translating laboratory MFRs to their solar counterparts enables quantitative investigations of CME initiation through laboratory experiments. These experiments allow for new physics insights that are required for better predictions of space weather events but are difficult to obtain otherwise.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Toroidal modeling of runaway electron loss due to 3D fields in ITER

Mitigation of runaway electrons (REs) by three-dimensional (3D) magnetic field perturbations is numerically investigated for the ITER 15 MA baseline D–T scenario, utilizing the MARS-F code (Liu et al Phys. Plasmas 7 3681) with a drift orbit test particle tracing module. Considered are two types of 3D fields: the n = 3 (n is the toroidal mode number) resonant magnetic perturbation (RMP) utilized for the purpose of controlling the edge localized modes in ITER, and perturbations generated by the n = 1 magneto-hydrodynamic (MHD) instabilities in a post-disruption plasma. The RMP field, applied to a pre-disruption plasma, is found to be moderately effective in mitigating the RE seeds in ITER when vacuum field model is assumed. Up to ~40% loss fraction is possible at 90 kA-turn coil current. The mitigation efficiency is however substantially reduced, down to less than 5%, when the plasma response is taken into account. This is due to strong screening of the resonant magnetic field components by the plasma response resulting in much less field line stochasticity. On the other hand, the MARS-F modeling, based on the DINA-simulated post-disruption equilibria, shows that the n = 1 resistive kink instabilities develop in these plasmas, as the edge safety factor qa evolves and drops below integer numbers. RE mitigation by these MHD instabilities is sensitive to the eigenmode structure. The best mitigation is achieved as q a drops below 3, when a global kink instability occurs that encompasses both internal and external components. This global instability is found to be capable of mitigating over 80% MeV-level passing RE orbits at a field perturbation |δB|/B 0 that is comparable to that observed in DIII-D experiments, and full mitigation if the perturbation amplitude is doubled. The 'wetted' area on the ITER limiting surface, due to MHD instability induced RE loss, generally increases with the perturbation amplitude (together with increasing loss fraction). At the highest perturbation level assumed in this study, the wetted area reaches ~60% of the total limiting surface area. Lastly, the lost RE orbits mainly strike the outer divertor region of the limiting surface, with some fraction also hitting a wide area along the inboard side of the surface.

3D fields↗
NASA NTRS1971

Lightning protection practices applied to field station installations

Theoretical considerations of lightning phenomena and the effects of the magnetic, capacitive, and resistive components of lightning-induced voltages are discussed. A typical tracking station is analyzed from a lightning standpoint. Specific protective methods are discussed, including the implementation of high-surge-current voltage clippers for sensitive electrical and electronic circuits, grounding, counterpoises, and bonding. The safety of operating personnel is also treated as a prime consideration.

Blalock, T. J.↗
DOE OSTI2021

Stability of beta-induced Alfvén eigenmodes (BAE) in DIII-D

Although the stability of ellipticity, toroidal and reversed-shear Alfvén eigenmodes (EAE, TAE, RSAE) are relatively well understood, less is known about the stability of lower-frequency modes such as the beta-induced Alfvén eigenmode (BAE) but, because they are often unstable in present devices and are implicated in fast-ion transport, understanding their stability is vital. BAE stability is studied in primarily weak or reversed shear DIII-D plasmas with sub-Alfvénic deuterium beams. Modes are classified based on electron cyclotron emission, beam emission spectroscopy, magnetics, and interferometer data. The study is limited to the initial two seconds of the discharge, where the evolving q profile provides an effective scan of the dependence of stability upon q. In a dedicated experiment, BAEs are unstable at times in the discharge when the minimum of the safety factor q min is close to a rational number. The observed mode frequencies are usually close to analytic estimates of the BAE accumulation point and the eigenfunction peaks in the vicinity of q min . Unstable BAEs usually occur in bursts that chirp rapidly in frequency. To isolate the importance of thermal and beam gradients in driving the modes, the beam and electron cyclotron heating power is altered for 50–100 ms durations in reproducible discharges. As expected from the resonance condition, BAEs depend sensitively on the beam power and injection geometry. Modes only persist for ~25 ms because the anisotropic beam population only interacts strongly with the modes over a relatively narrow range of q. Lastly, a database of over 1000 beam-heated discharges shows that BAEs are more likely to be unstable when the poloidal beta exceeds 0.5.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Unsupervised anomaly clustering via offset alignment in multivariate grid sensing data

Modern industries increasingly rely on multi-sensor technologies to acquire complex, high-dimensional data streams, enabling advanced monitoring and control systems. One critical application is online anomaly detection in electrical smart grids, where multivariate and multimodal sensing technologies play a vital role. However, detecting anomalies in such time-series data is challenging due to their inherent temporal dependencies and stochastic behavior. Traditional approaches based on supervised and semi-supervised learning methods depend on labeled datasets, which are often unavailable in real-world scenarios. While unsupervised methods have emerged as promising alternatives, these methods are highly susceptible to noise and outliers commonly present in sensing applications. Furthermore, deep learning-based anomaly detection methods, despite their performance, are often criticized for their black-box nature, limiting their applicability in safety-critical and online environments where interpretability and explainability are paramount. In this work, we propose an unsupervised anomaly clustering method leveraging a cyclic alignment-based offset detection algorithm for multivariate time-series signals. The proposed method is applied to multivariate data collected from vibrational, voltage, and magnetic field sensors deployed in a local grid substation. Our results demonstrate the robustness of the algorithm in accurately clustering various anomalies/events across different sensing modalities. Additionally, we compare the effectiveness of the proposed approach against a simple pattern-based anomaly detection method, which performs well for univariate data but fails to generalize to multivariate and multimodal time-series data.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2021

Design of High Power Density 100 kW Surface Permanent Magnet Machine with No Heavy Rare Earth Material Using Current Source Inverter for Traction Application

Surface permanent magnet (SPM) machines are appealing candidates for traction applications because of high power density and high efficiency. Rare-earth magnets deliver high performance but raise concerns about material supply dependability, particularly if they use heavy rare-earth materials. This paper presents the design of a high-performance SPM machine without any heavy rare-earth material that is optimized specifically for a current-source inverter (CSI) traction drive. This machine is designed for a constant-power speed ratio (CPSR) of 3. A genetic algorithm has been performed to achieve a target of 50 kW/L active power density at speeds up to 20,000 rpm. Operation at a peak line-to-line voltage of 800 V can be achieved using 1200 V power devices with a safety margin. The predicted electromagnetic and rotor structural performance characteristics are presented using both analytical and finite element analysis (FEA) results.

(CPSR)↗
DOE OSTI2024

Warm Unit Stand Assembly and Testing for Proton Improvement Plan - II

The Proton Improvement Project II (PIP II), situated at Fermilab, signifies a critical advancement in the realm of high-energy physics. PIP II, a linear accelerator renovation endeavor, aspires to double the output of the existing proton beam, reinforcing Fermilab’ s position as a vanguard in this field. The proton beam's creation involves a series of high-frequency cryomodules, necessitating environmental temperature arrays of magnets and vacuum pumps henceforth described as ‘Warm Units.’ The Warm Units include design features of : 1. insertion between the cryomodules, 2. multi-stage adjustments in six degrees of freedom to ensure precise beam alignment; 3. Natural frequency modes that avoid specified ranges. In adherence to Fermilab’ s stringent safety standards, comprehensive testing procedures are slated to validate the Warm Units' capacity to simultaneously achieve local alignment adjustments while averting low-frequency oscillation less than 15 Hertz. The testing regimen will scrutinize the Warm Units' alignment adjustment capabilities and their resilience against low-frequency oscillations, with an overarching objective of satisfying the Final Design Review criteria specific to the PIP II initiative. This project works to furnish technicians responsible for the assembly of Warm Units with a comprehensive guide for successful installation, concurrently documenting any requisite design modifications essential for achieving a real-world configuration.

43 PARTICLE ACCELERATORS↗
NASA NTRS2009

Wireless Fluid-Level Sensors for Harsh Environments

Magnetic-field-response sensors have been developed for use in measuring levels of fluids under extreme conditions. The sensors work without wire connections or direct physical contact with power sources, microprocessors, data-acquisition equipment, or electrical circuitry. For fuel-level sensors, the absence of wire connections offers an important safety advantage in elimination of potential ignition sources.

Woodward, Stanley E.↗
NASA NTRS2013

NASA Tech Briefs, April 2013

Topics covered include: Fully Integrated, Miniature, High-Frequency Flow Probe Utilizing MEMS Leadless SOI Technology; Nanoscale Surface Plasmonics Sensor With Nanofluidic Control; Advanced Dispersed Fringe Sensing Algorithm for Coarse Phasing Segmented Mirror Telescopes; Neural Network Back-Propagation Algorithm for Sensing Hypergols; Bulk Moisture and Salinity Sensor; Change-Based Satellite Monitoring Using Broad Coverage and Targetable Sensing; Circularly Polarized Microwave Antenna Element with Very Low Off-Axis Cross-Polarization; Ultra-Low Heat-Leak, High-Temperature Superconducting Current Leads for Space Applications; Flash Cracking Reactor for Waste Plastic Processing; An Automated Safe-to-Mate (ASTM) Tester; Wireless Chalcogenide Nanoionic-Based Radio-Frequency Switch; Compute Element and Interface Box for the Hazard Detection System; DOT Transmit Module; Composite Aerogel Multifoil Protective Shielding; Li-Ion Electrolytes with Improved Safety and Tolerance to High-Voltage Systems; Polymer-Reinforced, Non-Brittle, Lightweight Cryogenic Insulation; Controlled, Site-Specific Functionalization of Carbon Nanotubes with Diazonium Salts; Regenerable Sorbent for CO2 Removal; Sprayable Aerogel Bead Compositions With High Shear Flow Resistance and High Thermal Insulation Value; Lexan Linear Shaped Charge Holder with Magnets and Backing Plate; Robotic Ankle for Omnidirectional Rock Anchors; Wind, Wave, and Tidal Energy Without Power Conditioning; An Active Heater Control Concept to Meet IXO Type Mirror Module Thermal-Structural Distortion Requirement; Waterless Clothes-Cleaning Machine; Integrated Electrical Wire Insulation Repair System; LVGEMS Time-of-Flight Mass Spectrometry on Satellites; Surface Inspection Tool for Optical Detection of Surface Defects; Per-Pixel, Dual-Counter Scheme for Optical Communications; Certification-Based Process Analysis; Surface Navigation Using Optimized Waypoints and Particle Swarm Optimization; Smart-Divert Powered Descent Guidance to Avoid the Backshell Landing Dispersion Ellipse; Estimating Foreign-Object-Debris Density from Photogrammetry Data; Adaptive Sampling of Spatiotemporal Phenomena with Optimization Criteria; Building a 2.5D Digital Elevation Model From 2D Imagery; Eyes on the Earth 3D; Target Trailing With Safe Navigation for Maritime Autonomous Surface Vehicles; Adams-Based Rover Terramechanics and Mobility Simulator - ARTEMIS; ISTP CDF Skeleton Editor; Uplink Summary Generator (ULSGEN) Version 1.0; Robotics On-Board Trainer (ROBoT); Software Engineering Tools for Scientific Models; Automatic Data Filter Customization Using a Genetic Algorithm; Tracker Toolkit; Towards Efficient Scientific Data Management Using Cloud Storage; On a Formal Tool for Reasoning About Flight Software Cost Analysis; A Nanostructured Composites Thermal Switch Controls Internal and External Short Circuit in Lithium Ion Batteries; Spacecraft Crew Cabin Condensation Control; and Functional Near-Infrared Spectroscopy Signals Measure Neuronal Activity in the Cortex.

Source record↗
DOE OSTI2020

Results from the Alfvén Eigenmode Active Diagnostic during the 2019-2020 JET deuterium campaign

This paper presents results of extensive analysis of mode excitation observed during the operation of the Alfvén Eigenmode Active Diagnostic (AEAD) in the JET tokamak during the 2019-2020 deuterium campaign. Here, six of eight toroidally spaced antennas, each with independent power and phasing, were successful in actively exciting stable MHD modes in 479 plasmas. In total, magnetic resonances were detected with up to fourteen fast magnetic probes. In this work, we present the calculations of resonant frequencies $f_0$, damping rates γ < 0, and toroidal mode numbers $\textit{n}$, spanning the parameter ranges $f_0$ ≈ 30–250 kHz, –γ ≈ 0–13 kHz, and $\vert n \vert \leq {30}$. In general, good agreement is seen between the resonant and the calculated toroidal Alfvén Eigenmode frequencies, and between the toroidal mode numbers applied by the AEAD and estimated of the excited resonances. We note several trends in the database: the probability of resonance detection decreases with plasma current and external heating power; the normalized damping rate increases with edge safety factor but decreases with external heating. These results provide key information to prepare future experimental campaigns and to better understand the physics of excitation and damping of Alfvén Eigenmodes in the presence of alpha particles during the upcoming DT campaign, thereby extrapolating with confidence to future tokamaks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Adrian Portales Coop Internship Report

Using the thesis of W.R. Nolan (cite) as a guide, Cobalt Iron (CoFe) powders were reacted with 0.1 wt.% and 0.2 wt.% phosphoric acid in a 20:1 ratio of acetone to phosphoric acid. The powders were then dried at room temperature. The resulting phosphate coated CoFe was then mixed with 0.75 wt.% of the lubricant N,N' ethylene bis-stearamide (trade name: Acrawax C) and hot pressed to form a consolidated soft magnetic material referred to as CoFeP. With an avenue of synthesis for CoFeP determined, a proper amount of stock was synthesized for continuous “brick” production. While under current optimization, these 1x1 mm magnetic bricks will ultimately be placed and secured along the inside wall of each MK Magnetics transformer core by an appropriate CoFeP dispersed epoxy. As of now each brick has been produced though a pressing and annealing process via square 2x2 cm die. Before a brick is made a pressure calculation is run to ensure the dies maximum operating pressure is not exceeded. Figure 1. ensures the user’s safety by showing that the tons-on-ram required for a 2x2 cm square die to reach 760 MPa is below the point of die failure.

36 MATERIALS SCIENCE↗