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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Photonic curing of solution-deposited ZrO 2 dielectric on PEN: a path towards high-throughput processing of oxide electronics

High-throughput manufacturing of oxide electronics will enable new applications ranging from large-area displays to flexible medical devices and low-cost solar panels. However, high quality oxide films from solution-based precursors typically require 20 minutes or more of thermal annealing at high temperature (> 250 °C) for each layer, severely limiting both the throughput and substrate choice. Here, we report high speed photonic curing of ZrO 2 dielectric thin films on flexible plastic substrates. The curing and patterning processes can be achieved simultaneously by using shadow mask patterning or adjusting conditions to convert oxide only on top of underlying metal contacts, i.e. self-aligned patterning. Metal-insulator-metal capacitors using two layers of ZrO 2 films photonically cured in just 100 seconds per layer show non-dispersive capacitance-frequency behavior from 10 2 to 10 6 Hz, high areal capacitance of 200 nF/cm 2 and low dissipation factor of 0.03 at 10 5 Hz, leakage current density of ~ 10 -7 A/cm 2 at an applied field of 2 MV/cm, and a breakdown field of nearly 8 MV/cm. Using an upgraded tool, similar dielectric properties are achieved in as short as 100 milliseconds using a single pulse of light, revealing a pathway to oxide film processing beyond 30 m/min.

14 SOLAR ENERGY↗
DOE OSTI2025

Insights into determining pore size properties of ultrafiltration membranes

The selectivity of porous membranes is often characterized using solute rejection tests, where membranes are challenged with dilute aqueous solutions of neutral solutes at operating conditions that minimize concentration polarization and fouling. In single solute tests, a membrane is challenged with one molecular weight (MW) solute at a time from low to high MW. Since single solute methods are time-intensive, mixed solute tests have become more common, where a mixture of several MW solutes challenges a membrane at once. However, the presence of large solutes in a mixture increases the rejection of smaller solutes. Furthermore, there are no universally accepted operating conditions or standard methods used by membrane manufacturers or researchers for the experiments, leading to difficulty in pore size and pore characteristic comparisons. In this paper, commercial ultrafiltration membranes were challenged with single and mixed solute polyethylene glycol (PEG) and dextran aqueous solutions. First, rejection values determined using total organic carbon (TOC) and high-performance liquid chromatography (HPLC) from single solute filtration experiments are compared. Differences in rejection curves obtained by the two techniques are attributed to solute polydispersity. Mixed solute filtration experiments with binary mixtures of solutes showcased co-solute interactions, which increase with both the size and weight percent of large solute in the mixture. Mixed solute filtration experiments at varying operating conditions (i.e., stir speed and flux) were conducted to determine operating conditions that mitigate co-solute interactions. Stir speed had a minimal effect on co-solute interactions. In contrast, low flux conditions can help minimize co-solute interactions, leading to pore size distributions that closely resemble results observed in single solute filtration using narrowly dispersed solutes. Additionally, at low flux conditions, the predicted membrane pore size distributions utilizing mixed solute experiments with PEG and dextran were similar.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multifunctional reactive inks, methods of use and manufacture thereof

In one embodiment, a method includes dispersing a plurality of particles in solution to form a dispersion and adding a stabilizing agent to the dispersion in an amount sufficient to cause the dispersion to exhibit one or more predetermined rheological properties. The particles in the dispersion are configured to complete a self-propagating and/or self-sustaining reaction upon initiation thereof. In another embodiment, a method includes depositing a material on a substrate. The material includes: a plurality of particles configured to complete a self-propagating and/or self-sustaining reaction upon initiation thereof, a solvent system, and one or more stabilizing agents.

Sullivan, Kyle T.↗
DOE OSTI2021

Printing thermoelectric inks toward next-generation energy and thermal devices

The ability of thermoelectric (TE) materials to convert thermal energy to electricity and vice versa highlights them as a promising candidate for sustainable energy applications. Despite considerable increases in the figure of merit zT of thermoelectric materials in the past two decades, there is still a prominent need to develop scalable synthesis and flexible manufacturing processes to convert high-efficiency materials into high-performance devices. Scalable printing techniques provide a versatile solution to not only fabricate both inorganic and organic TE materials with fine control over the compositions and microstructures, but also manufacture thermoelectric devices with optimized geometric and structural designs that lead to improved efficiency and system-level performances. In this review, we aim to provide a comprehensive framework of printing thermoelectric materials and devices by including recent breakthroughs and relevant discussions on TE materials chemistry, ink formulation, flexible or conformable device design, and processing strategies, with an emphasis on additive manufacturing techniques. Additionally, we review recent innovations in the flexible, conformal, and stretchable device architectures and highlight state-of-the-art applications of these TE devices in energy harvesting and thermal management. Perspectives of emerging research opportunities and future directions are also discussed. While this review centers on thermoelectrics, the fundamental ink chemistry and printing processes possess the potential for applications to a broad range of energy, thermal and electronic devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Solid Solvation Assisted Electrical Doping Conserves High‐Performance in 500 nm Active Layer Organic Solar Cells

Abstract Organic solar cells (OSCs) process fascinating solution‐printing capability to achieve low‐cost and large‐scale manufacture. However, the rapid power conversion efficiency (PCE) decay with active layer thickness enlargement inhibits the implement of OSCs’ potential advantages. To overcome the bottlenecks of PCE decay in thick active layer OSCs, the electrical doping with componential selectivity in bulk heterojunction (BHJ) film is achieved by introducing a solid solvation additive. Benefiting from the higher exciton splitting efficiency together with the longer drift (L dr ) and diffusion (L diff ) lengths, an OSC with 100 nm BHJ film demonstrates a PCE increment from 16.44% to 18.24% with prolonged dark and illuminated storage stabilities. Applying the solid solvation assisted (SSA) doping method in the OSCs with 500 nm active layer, the PCE significantly increases by 31.9%, from the original value of 11.79% to 15.55%. It further improves to 15.84% in a ternary blend thick‐film device, which is the record value to the best of our knowledge. Besides, the SSA doping narrows the PCE gap between the 0.04 and 1 cm 2 devices. All improvements demonstrate the great potential of SSA doping for OSC commercial manufacture, since it optimizes the photovoltaic performance under all practical conditions of long‐term, thick‐film, and large‐area.

Chemistry↗
DOE OSTI2021

Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Ceramic nanograined materials have desirable characteristics compared to their macroparticle counterparts but are rarely used in industrial applications due to issues with poor handleability and health hazards. Due to interparticle forces that become more dominant as the particle size decreases, it is difficult to use nanomaterials to fill dies, spread on surfaces, or flow through hoppers found in various manufacturing processes. In this work, we report a scalable gelcasting solution and unique emulsification process to create microspheres composed of nanoscale powders to enhance the flowability and handleability of nanomaterials. The gelcasting solution and emulsification process can be used with any nanoparticle composition that can be suspended in a liquid phase. This paper reports the effects of various parameters on zirconium diboride microsphere formation, such as surfactant content and mixing conditions. The microspheres maintain the nano-scale characteristics of the powder but improve its flowability by using cross-linked polyvinyl alcohol to combine irregularly shaped zirconium diboride nanoparticles with a particle diameter of 60 nm into larger spherical particles with a d 50 ~25 μm. This hierarchical feedstock engineering design combine the positive characteristics of materials across both length scales and improve the flowability of the feedstock from a Hausner Ratio of 1.56 to 1.19. The materials produced using this technique can be used in thermal plasma spray, die filling for hot pressing or spark plasma sintering, and binder jet printing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Surface engineering of polymeric membranes with metal oxides for improved fouling resistance and superior oil-water separation

Rapid industrial growth has increased the need for efficient membranes to separate oil-water emulsions. Polyvinylidene fluoride (PVDF) membranes, although widely used due to their chemical inertness and favorable mechanical properties, suffer from fouling due to their intrinsic hydrophobicity. Modifying these membranes after fabrication offers a practical solution as it easily fits into existing large-scale manufacturing processes. Atomic layer deposition (ALD), an atomically-precise vapor phase surface modification technique, can create ultrathin metal oxide layers that greatly improve membrane hydrophilicity without significantly affecting the original pore size. However, PVDF's lack of reactive chemical moieties makes ALD challenging. Here, in this study, we present a simple alkali treatment that greatly enhances ALD nucleation and growth on PVDF membranes. This treatment imparts exceptional oil-water emulsion separation capabilities and antifouling behavior in PVDF membranes after just a few ALD cycles, surpassing the performance of PVDF membranes coated with hundreds of ALD cycles. This dramatic reduction in the number of ALD cycles required could enable cost-effective modification of commercial PVDF membranes at scale using spatial, roll-to-roll ALD. These modified membranes outperform reported modified PVDF membranes, with >99 % permeance recovery and <1 % irreversible loss of permeance and >98 % oil rejection from oil-water emulsions over 100 h continuous operation, making them promising for advanced water purification technologies.

Atomic layer deposition↗
DOE OSTI2023

Uncertainty quantification in machine learning for engineering design and health prognostics: A tutorial

On top of machine learning (ML) models, uncertainty quantification (UQ) functions as an essential layer of safety assurance that could lead to more principled decision making by enabling sound risk assessment and management. The safety and reliability improvement of ML models empowered by UQ has the potential to significantly facilitate the broad adoption of ML solutions in high-stakes decision settings, such as healthcare, manufacturing, and aviation, to name a few. In this tutorial, we aim to provide a holistic lens on emerging UQ methods for ML models with a particular focus on neural networks and the applications of these UQ methods in tackling engineering design as well as prognostics and health management problems. Towards this goal, we start with a comprehensive classification of uncertainty types, sources, and causes pertaining to UQ of ML models. Next, we provide a tutorial-style description of several state-of-the-art UQ methods: Gaussian process regression, Bayesian neural network, neural network ensemble, and deterministic UQ methods focusing on spectral-normalized neural Gaussian process. Established upon the mathematical formulations, we subsequently examine the soundness of these UQ methods quantitatively and qualitatively (by a toy regression example) to examine their strengths and shortcomings from different dimensions. Then, we review quantitative metrics commonly used to assess the quality of predictive uncertainty in classification and regression problems. Afterward, we discuss the increasingly important role of UQ of ML models in solving challenging problems in engineering design and health prognostics. In conclusion, two case studies with source codes available on GitHub are used to demonstrate these UQ methods and compare their performance in the life prediction of lithium-ion batteries at the early stage (case study 1) and the remaining useful life prediction of turbofan engines (case study 2).

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Selective permeation up a chemical potential gradient to enable an unusual solvent purification modality

The need for energy-efficient recovery of organic solutes from aqueous streams is becoming more urgent as chemical manufacturing transitions toward nonconventional and bio-based feedstocks and processes. In addition to this, many aqueous waste streams contain recalcitrant organic contaminants, such as pharmaceuticals, industrial solvents, and personal care products, that must be removed prior to reuse. We observe that rigid carbon membrane materials can remove and concentrate organic contaminants via an unusual liquid-phase membrane permeation modality. Surprisingly, detailed thermodynamic calculations on the chemical potential of the organic contaminant reveal that the organic species has a higher chemical potential on the permeate side of the membrane than on the feed side of the membrane. This unusual observation challenges conventional membrane transport theory that posits that all permeating species move from high chemical potential states to lower chemical potential states. Based on experimental measurements, we hypothesize that the organic is concentrated in the membrane relative to water via favorable binding interactions between the organic and the carbon membrane. The concentrated organic is then swept through the membrane via the bulk flow of water in a modality known as “sorp-vection.” We highlight via simplified nonequilibrium thermodynamic models that this “uphill” chemical potential permeation of the organic does not result in second-law violations and can be deduced via measurements of the organic and water sorption and diffusion rates into the carbon membrane. Moreover, this work identifies the need to consider such nonidealities when incorporating unique, rigid materials for the separations of aqueous waste streams.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Coupling a Lagrangian–Eulerian Spark-Ignition (LESI) model with LES combustion models for engine simulations

In the United States transportation sector, Light-Duty Vehicles (LDVs) are the largest energy consumers and CO 2 emitters. Electrification of LDVs is posed as a potential solution, but SI engines can still contribute to decarbonization. Car manufacturers have turned to unconventional engine operation to increase the efficiency of Spark-Ignition (SI) engines and reduce the carbon emissions of their fleets. Dilute, lean, and stratified-charge engine operation has the potential for engine efficiency improvements at the expense of increased cyclic variability and combustion instability. At such demanding engine conditions, the spark ignition event is key for flame initiation and propagation and for enhanced combustion stability. Reliable and accurate spark ignition models can help design ignition systems that reduce cyclic variability. Multiple computational spark-ignition models exist that perform well under conventional conditions, but the underlying physics needs to be expanded, for unconventional engine operation. In this paper, a hybrid Lagrangian–Eulerian Spark-Ignition (LESI) model is coupled with different turbulent flame propagation models for engine simulations. LESI relies on Lagrangian arc tracking and Eulerian energy deposition. The LESI model is coupled with the Well-Stirred Reactor (WSR), Thickened Flame Model (TFM), and g-equation model and used to simulate several cycles of a Direct-Injection Spark-Ignition (DISI) engine using a commercial Computational Fluid Dynamics (CFD) engine solver. The results showcase the successful coupling of LESI with the combustion models. Global engine metrics, such as pressure and Apparent Heat Release Rate (AHRR), for each simulation setup are compared to experimental engine results, for validation. In addition, results highlight the successful prediction of spark channel movement by comparing simulation images to experimental optical engine images. Finally, the successful coupling of LESI to combustion models, making it a usable model in the engine modeling community, is emphasized and future development details are discussed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants

The recently released Circularity Gap Report 2023 by Circle Economy Foundation found that the circularity score for the global economy is declining. This indicates that material extraction from virgin sources is climbing over earlier years. As per data released by US Geological Survey, material use in the US economy has increased exponentially with the expanding US economy over last century. EPA tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste is destined for landfills. EPA estimates that US industry is responsible for 2.7 billion ton of solid non-hazardous waste annually in our mostly linear economy model. The circular economy framework aims at decoupling economic value generation from virgin materials extraction from nature. The linear model of material extraction and disposal at end of life is highly unsustainable. Manufacturing companies have realized this and in their commitments to sustainability are adopting ambitious waste reduction targets. Through Better Plants program US Department of Energy has established Waste Reduction Network where it is offering technical assistance to partners to achieve these ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is the unstandardized metrics to quantify waste performance that may not be well suited to demonstrate progress. In this paper, we research methods traditionally used to measure waste performance and highlight advantages, gaps and limitations of each method. Suitability of the methods applicable to different manufacturing circumstances are also examined. Finally, we present a case study of a large manufacturer that faced inconsistencies in their tracked measurement metric. A solution was proposed to alter the methodology to enable more accurate waste performance tracking against a baseline.

Chaudhari, Subodh↗
DOE OSTI2021

Comparison of the Mechanical Properties of a Conjugated Polymer Deposited Using Spin Coating, Interfacial Spreading, Solution Shearing, and Spray Coating

The mechanical properties of π-conjugated (semiconducting) polymers are a key determinant of the stability and manufacturability of devices envisioned for applications in energy and healthcare. These properties—including modulus, extensibility, toughness, and strength—are influenced by the morphology of the solid film, which depends on the method of processing. To date, the majority of work done on the mechanical properties of semiconducting polymers has been performed on films deposited by spin coating, a process not amenable to the manufacturing of large-area films. Here, we compare the mechanical properties of thin films of regioregular poly(3-heptylthiophene) (P3HpT) produced by three scalable deposition processes—interfacial spreading, solution shearing, and spray coating—and spin coating (as a reference). Our results lead to four principal conclusions. (1) Spray-coated films have poor mechanical robustness due to defects and inhomogeneous thickness. (2) Sheared films show the highest modulus, strength, and toughness, likely resulting from a decrease in free volume. (3) Interfacially spread films show a lower modulus but greater fracture strain than spin-coated films. (4) The trends observed in the tensile behavior of films cast using different deposition processes held true for both P3HpT and poly(3-butylthiophene) (P3BT), an analogue with a higher glass transition temperature. Grazing incidence X-ray diffraction and ultraviolet–visible spectroscopy reveal many notable differences in the solid structures of P3HpT films generated by all four processes. Herein, while these morphological differences provide possible explanations for differences in the electronic properties (hole mobility), we find that the mechanical properties of the film are dominated by the free volume and surface topography. In field-effect transistors, spread films had mobilities more than 1 magnitude greater than any other films, likely due to a relatively high proportion of edge-on texturing and long coherence length in the crystalline domains. Overall, spread films offer the best combination of deformability and charge-transport properties.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Draft ASME Code Case to qualify L-PBF 316H material for Section III, Division 5 applications

This report documents the AMMT program’s development and submission of a draft ASME Code Case to qualify Laser Powder Bed Fusion (L PBF) Type 316H stainless steel for Section III, Divi-sion 5 Class A and SM high temperature nuclear applications. It summarizes the technical basis, the comprehensive high temperature mechanical test database assembled between 2023–2026, and the proposed code language and qualification framework submitted to ASME. The work was co-ordinated across multiple national laboratories and leverages prior ASME efforts to integrate additive manufacturing into the Boiler & Pressure Vessel Code. The body of the report describes the experimental database and analysis supporting the Code Case: tensile, creep, fatigue, creep fatigue, and thermal aging tests collected from multiple additive manufacturing sites, machine types, and powder lots, with material processed by a solution anneal heat treatment. The dataset — including both full size and subsized specimens and tests oriented parallel and perpendicular to build direction — shows limited tensile anisotropy, tensile properties comparable to wrought 316H, creep strength within the scatter of wrought material, but markedly reduced creep ductility above about 650 °C associated with rapid σ phase formation in L PBF microstructures. The draft Code Case itself prescribes a staged qualification model (manufacturing process qualification, component qualification, and per build witness testing), treats L PBF components as equivalent to Type 316 weld metal for design and inspection, and requires mechanical, chemical, and metallographic controls tied to ASTM/ISO 52946. Key acceptance criteria include tensile tests within a 90% prediction interval of the AMMT dataset, a creep fatigue screening test adapted from ASME Section III, Division 5, Subsection HB, HBB 2800 but with the cycle acceptance reduced to 100 for L PBF material, and double volumetric inspection of production components. The report concludes that the present data support treating L PBF 316H as analogous to conventional fusion weld metal for Division 5 design and inspection, while highlighting important caveats: the σ phase driven loss of creep ductility above ~650 °C, preliminary indications of enhanced creep fatigue sensitivity in some lots, and remaining gaps in long term aging and additional cyclic testing. Recommended next actions include completing outstanding cyclic and long duration creep/aging tests on the solution annealed condition, supporting inclusion of the 316H chemistry and heat treatment in ASTM/ISO 52946, and continuing engagement with ASME and NRC during balloting and review to enable industry adoption.

Messner, Mark C. (ORCID:0000000200404385)↗
DOE OSTI2024

Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics

Abstract Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al alloy Al 92 Ti 2 Fe 2 Co 2 Ni 2 is fabricated by selective laser melting. Heterogeneous nanoscale medium-entropy intermetallic lamella form in the as-printed Al alloy. Macroscale compression tests reveal a combination of high strength, over 700 MPa, and prominent plastic deformability. Micropillar compression tests display significant back stress in all regions, and certain regions have flow stresses exceeding 900 MPa. Post-deformation analyses reveal that, in addition to abundant dislocation activities in Al matrix, complex dislocation structures and stacking faults form in monoclinic Al 9 Co 2 type brittle intermetallics. This study shows that proper introduction of heterogeneous microstructures and nanoscale medium entropy intermetallics offer an alternative solution to the design of ultrastrong, deformable Al alloys via additive manufacturing.

Science & Technology - Other Topics↗
DOE OSTI2026

Advancing Industry 4.0: Multimodal Sensor Fusion for AI-Based Fault Detection in 3D Printing

Additive manufacturing, particularly fused deposition modeling, is transforming modern production by enabling rapid prototyping and complex part fabrication. However, its layer-by-layer process remains vulnerable to faults such as nozzle clogging, filament runout, and layer misalignment, which compromise print quality and reliability. Traditional inspection methods are costly, time-intensive, and often limited to post-process analysis, making them unsuitable for real-time intervention. In this current study, the authors developed a novel, low-cost, and portable faultdetection system that leverages multimodal sensor fusion and artificial intelligence for real-time monitoring in FDM-based 3D printing. The system integrates acoustic, vibration, and thermal sensing into a non-intrusive architecture, capturing complementary data streams that reflect both mechanical and process-related anomalies. Acoustic and thermal sensors operate in a fully contactless manner, while the vibration sensor requires minimal attachment such that it will not interfere with printer hardware, thereby preserving portability and ease of deployment. The multimodal signals are processed into spectrograms and time-frequency features, which are classified using convolutional neural networks for intelligent fault detection. The proposed system advances Industry 4.0 objectives by offering an affordable, scalable, and practical monitoring solution that improves faultdetection accuracy, reduces waste, and supports sustainable, adaptive manufacturing.

42 ENGINEERING↗
DOE OSTI2026

Fabrication of ceramic to metal graded structure for high temperature CSP receiver application using solid state additive manufacturing

The overarching goal of this project is to come up with an innovative joining solution for integration of SiC ceramic to structural materials such as stainless steels (SS)/Ni-base alloys, where intimate metallurgical bonding between SiC ceramic and the structural metallic alloy is demonstrated at the interface. Implementation of a simple, yet robust joining method would help in increasing the application space of SiC in a high-temperature CSP (concentrated solar power) plant, especially in the receiver section. This research goal has been achieved by creating a functionally graded material (FGM) interface between SiC and the selected structural material with the help of powder metallurgy (PM) approach and demonstrate intimate metallurgical bonding between monolithic RB-SiC and 316L stainless steel alloy blanks.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Unlocking Manufacturing Sustainability: Energy Efficiency Opportunities through the US Department of Energy’s Better Plants Program Energy Treasure Hunts (2023–2024)

The US manufacturing sector faces critical challenges: improving sustainability, reducing energy consumption, and reducing greenhouse gas emissions. Energy Treasure Hunt (ETH) training, a service provided by the US Department of Energy’s Better Plants program, offers a compelling solution. Although ETHs have traditionally focused on energy and cost savings, data indicate that ETHs can be used to identify opportunities to reduce emissions and water use and to support a sustainable and circular operation. These 3-day on-site events engage employees in a collaborative search for operational and maintenance efficiency improvement opportunities. The success of ETHs lies in a comprehensive methodology. Each phase in an ETH uses various tools and resources to empower employees to identify practical solutions. This study presents data from 13 ETHs conducted between 2023 and 2024 across diverse manufacturing subsectors in the United States and demonstrates that the events can help create a pragmatic decarbonization pathway. Through the events, a total of 234 energy and emissions reduction opportunities were identified, and the potential impact is significant. Implementing the recommendations could translate to annual savings of 497,299 MMBtu of energy, 64,374 kgal of water, and 4.85 million tCO 2 e of emissions. The fiscal savings from the proposed recommendations translate into nearly $\$$5 million annually. This study identifies the opportunities by energy system type and by the specific actions recommended, while also analyzing the identified opportunities, presenting the most established sustainability recommendations. Case studies from participating partners are presented to further demonstrate that ETHs provide a practical and impactful approach to reducing energy consumption, emissions, and operating costs and promote a more sustainable future for the industrial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Testing of a 15 kA Superconducting Transformer

Here, the manufacturing of superconducting magnets for High Energy Physics (HEP) and Fusion Energy Sciences (FES) applications requires high-current conductors to generate stronger magnetic fields without increasing the inductance of the magnet. Increased inductance is undesirable due to the associated AC losses, which reduce the temperature margin; and the quench protection also becomes complicated. Testing high-current conductors with a direct current (DC) room temperature power supply is unfeasible for two primary reasons: 1) the limited capacity to supply large currents, and 2) the significant heat load losses at the current leads. A superconducting transformer offers a solution to both challenges. A 50-kA superconducting transformer is planned for manufacturing and commissioning at Brookhaven National Laboratory as part of its user facility upgrade. This transformer will facilitate the testing of superconducting cables, conductors, joints, and insert coils under high magnetic field conditions (10 T) and with currents up to 50-kA. To evaluate the manufacturing process and validate the theoretical models, the magnet division has developed and tested a 15-kA prototype transformer. A control loop has been implemented to ensure precise current delivery to the sample. This paper presents the coil design, manufacturing, and experimental results from the cold tests.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗