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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Summary of FY2024 Experimental Results to Support Development of New Inelastic Material Models and Validation of Section III, Division 5, Class A Design Rules

To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Mass measurement of 27 P to constrain type-I x-ray burst models and validate the isobaric multiplet mass equation for the $A = 27, T = \frac{3}{2}$ isospin quartet

Background: Light curves are the primary observable of type-I x-ray bursts. Computational x-ray burst models must match simulations to observed light curves. Most of the error in simulated curves comes from uncertainties in rp process reaction rates, which can be reduced via precision mass measurements of neutron-deficient isotopes in the rp process path. Purpose: Perform a precise atomic mass measurement of 27 P. Use this new measurement to calculate rp process reaction rates and input these rates into an x-ray burst model to reduce simulated light curve uncertainty. Use the mass measurement of 27 P to validate the isobaric multiplet mass equation (IMME) for the A = 27 T = 3/2 isospin quartet which 27 P belongs to. Method: High-precision Penning trap mass spectrometry utilizing the time-of-flight ion cyclotron resonance technique was used to determine the atomic mass of 27 P. The MESA code (Modules for Experiments in Stellar Astrophysics) was then used to simulate x-ray bursts using a one-dimensional multizone model to produce updated light curves. Results: The mass excess of 27 P was measured to be –670.7(6) keV, a 14-fold precision increase over the mass reported in the 2020 Atomic Mass Evaluation (AME2020). The 26 Si(p, $γ$) 27 P– 27 P($γ$, p) 26 Si rate equilibrium has been determined to a higher precision based on the precision mass measurement of 27 P. x-ray burst light curves were produced with the MESA code using the new reaction rates. Changes in the mass of 27 P seem to have minimal effect on light curves, even in burster systems tailored to maximize impact. Conclusion: The mass of 27 P does not play a significant role in x-ray burst light curves. It is important to understand that more advanced models do not just provide more precise results, but often qualitatively different ones. This result brings us a step closer to being able to extract stellar parameters from individual x-ray burst observations. In addition, the IMME has been validated for the A = 27, T = 3/2 quartet. The normal quadratic form of the IMME using the latest data yields a reduced $χ$ 2 of 2.9. Finally, the cubic term required to generate an exact fit to the latest data matches theoretical attempts to predict this term.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Perturbation theory for modeling galaxy bias: validation with simulations of the Dark Energy Survey

We describe perturbation theory (PT) models of galaxy bias for applications to photometric galaxy surveys. We model the galaxy-galaxy and galaxy-matter correlation functions in configuration space and validate against measurements from mock catalogs designed for the Dark Energy Survey (DES). We find that an effective PT model with five galaxy bias parameters provides a good description of the 3D correlation functions above scales of 4 Mpc/$h$ and $z < 1$. Our tests show that at the projected precision of the DES-Year 3 analysis, two of the non-linear bias parameters can be fixed to their co-evolution values, and a third (the $k^2$ term for higher derivative bias) set to zero. The agreement is typically at the 2 percent level over scales of interest, which is the statistical uncertainty of our simulation measurements. To achieve this level of agreement, our {\it fiducial} model requires using the full non-linear matter power spectrum (rather than the 1-loop PT one). We also measure the relationship between the non-linear and linear bias parameters and compare them to their expected co-evolution values. We use these tests to motivate the galaxy bias model and scale cuts for the cosmological analysis of the Dark Energy Survey; our conclusions are generally applicable to all photometric surveys.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Advancing Offshore Wind Resource Characterization Using Buoy-based Observations

As countries continue to implement sustainable and renewable energy goals, the need for affordable low-carbon technologies, including those related to offshore wind energy, is accelerating. The U.S. federal government recognizes the environmental and economic benefits of offshore wind development and is taking the necessary steps to overcome critical challenges facing the industry to realize these benefits. The U.S. Department of Energy (DOE) is investing in buoy-mounted lidar systems to facilitate offshore measurement campaigns that will advance our understanding of the offshore environment and provide the observational data needed for model validation, particularly at hub height where offshore observations are particularly lacking. On behalf of the DOE, Pacific Northwest National Laboratory manages a Lidar Buoy Program that facilitates meteorological and oceanographic data collection using validated methods to support the U.S. offshore wind industry. Since being acquired in 2014, two DOE lidar buoys have been deployed on the U.S. east and west coasts; and their data represent the first publicly available multi-seasonal hub height data to be collected in U.S. waters. In addition, the buoys have undergone performance testing, significant upgrades, and a lidar validation campaign to ensure the accuracy and reliability of the lidar data needed to support wind resource characterization and model validation. The Lidar Buoy Program is providing valuable offshore data to the wind energy community, while focusing data collection on areas of acknowledged high priority.

offshore wind energy, lidar buoy, wind resource ch↗
DOE OSTI2023

Voltage-Based Strategies for Preventing Battery Degradation under Diverse Fast-Charging Conditions

Maintaining safe operating conditions is a key challenge for high-performance lithium-ion battery applications. The lithium-plating reaction remains a risk during charging, but limited studies consider the highly variable charging conditions possible in commercial cells. Here we combine pseudo-2D electrochemical modeling with data visualization methods to reveal important relationships between the measurable cell voltage and difficult-to-predict Li-plating onset criteria. An extensively validated model is used to compute Li plating for thousands of multistep charging conditions spanning diverse rates, temperatures, states-of-charge, and cell aging. Here we observe an empirical cell operating voltage limit below which plating does not occur across all conditions, and this limit varies with the battery state-of-charge and aging. A model sensitivity analysis also indicates that, when comparing two charging voltage profiles, the capacity difference at 4.0 V correlates well with the difference in the plating onset capacity. These results encourage simple strategies for Li-plating prevention that are complementary to existing battery controls.

25 ENERGY STORAGE↗
DOE OSTI2024

High-Temperature Fe-Based Fischer–Tropsch Synthesis: Experimentally Validated Kinetic Models Implemented at Pellet and Reactor Scales

Pellet- and reactor-scale models for Fischer–Tropsch synthesis (FTS) with a Fe–K/silica catalyst were developed to investigate the sensitivity of the hydrocarbon products and carbon dioxide selectivity to process conditions and feed composition at high temperature (350–400 °C), moderate pressure (1–10 bar), and a range of H 2 /CO ratios (3–1). The major objective of this paper is to develop, validate, and evaluate a high-temperature FTS model that is then used to assess the feasibility of process integration with syngas production. Since there is limited kinetic data available, in literature at these conditions, bench-scale reactor tests were conducted to obtain operational data for parameter fitting of kinetic expressions used in the model. This resulting kinetic model demonstrated agreement with the experimental data with an R 2 of 0.97 to the testing data set and, thus, was feasible to apply at pellet and reactor scales. Here, multiple pellet sizes were modeled to detail the role of transport limitations as the sphere’s diameter approached and exceeded 1 mm. Application of the reactor model indicated that hydrocarbon selectivity depended strongly on temperature, whereas the ratio of olefin to paraffin products decreased with increasing temperature, pressure, and H 2 /CO ratio. Product selectivity was not sensitive to the conversion of carbon monoxide. Furthermore, the roles of the pressure and H 2 /CO ratio were closely coupled. At a H 2 /CO ratio of 3, only slight variations in selectivity occurred over a pressure range of 1–20 bar, whereas at a ratio of 1, selectivity could vary by as much as 30% over the same pressure range. At pressures below 5 bar and temperatures above 350 °C, minimal selectivity to heavy hydrocarbons (C 12+ ) is obtained, and selectivity to midrange products (C 5–11 ) rapidly declined as pressure dropped below 5 bar, which indicated that an operational pressure of at least 5 bar is needed to achieve reasonable yields in this temperature range. These results, while tentative, provide guidelines for further experimentation and evaluation of integrated FTS processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Hydropower Black Start: A Guidebook for Retrofitting Grid Dependent Hydropower

Not all United States (US) hydropower plants were designed to provide black start, but they are increasingly needed to uphold resilience in the evolving electric grid. This guidance is designed to help understand the minimal retrofits required for grid dependent hydropower (GDH) plants behind the point of interconnection (POI). For distribution connected hydropower plants or those with dedicated cranking paths, such upgrades can be sufficient for the plant to provide black start. For others, more coordination with the transmission system operator will be needed. This guidebook answers a number of questions relevant to retrofitting hydropower plants with black start capabilities. For example, the guidebook answers: • How flexible do the wicket gate controls need to be? • Who needs to do hydro governor model validation, why, and how? • How robust and flexible do the excitation and AVR controls need to be? • What protection settings need to be adjusted? • What relay(s) will need to be bypassed or overridden and at what risk? • What is the electrical energy demand of the station load or auxiliary power systems? • What should the strategy to energize transformer(s) along cranking path to address inrush currents be? • How should the critical load restoration be sequenced? In addition to outlining the specifications that hydropower plants need to meet for each component to be able to perform black start, this guidebook provides a set of case studies for specific upgrades needed at actual plants. Between the case studies of plants that have already performed black start retrofits and the examples of how this guidebook can be applied to scope future retrofits, five key themes have been identified for retrofit needs. 1. Protection needs “black start” mode: hydropower plants that are not designed with black start capabilities will have protections that prevent them from interconnecting to a “dead bus.” These protections will need to be overridden in every retrofit case and a separate black start mode should be established so that operators can safely switch between black start and grid connected modes, minimizing the risk to the plant. 2. Wicket gates need modern controls: digital governors accelerate the parameter tuning process and gate position sensors improve controllability, so plants with mechanical governors should be upgraded. Furthermore, a black start and islanding mode should be established for controls to maximize plant performance. 3. Robust excitation support: the DC system or excitation generator needs to be reliable enough to form and sustain the rotor electromagnetic field. These systems are typically undersized in plants that were not designed for black start, so they will need to be upgraded. 4. Turbine-governor model validation and operator training: validation of a standard hydro governor model is needed to characterize the dynamic response (i.e., inertial and primary frequency response) of the GDH. This is required for control development and old hydropower plants often have outdated or incorrect models. Operator training is also typically required to ensure the hardware retrofits are utilized correctly during the black start process. 5. Transformer and cranking path energization: any upgradation and control adjustment in front of the POI will depend upon the existing interconnection. Coordination with the transmission or distribution operator may be required.

13 HYDRO ENERGY↗
DOE OSTI2024

Validation Assessment of Turbulent Reacting Flow Model Using The Area-Validation Metric on Medium-Scale Methanol Pool Fire Results

Accident analysis and ensuring power plant safety are pivotal in the nuclear energy sector. Significant strides have been achieved over the past few decades regarding fire protection and safety, primarily centered on design and regulatory compliance. Yet, after the Fukushima accident a decade ago, the imperative to enhance measures against fire, internal flooding, and power loss has intensified. Hence, a comprehensive, multilayered protection strategy against severe accidents is needed. Consequently, gaining a deeper insight into pool fires and their behavior through extensive validated data can greatly aid in improving these measures using advanced validation techniques. A model validation study was performed at Sandia National Laboratories in which a 30-cm diameter methanol pool fire was modeled using the SIERRA/Fuego turbulent reacting flow code. This validation study used a standard validation experiment to compare model results against, and conclusions have been published. The fire was modeled with a Large Eddy Simulation (LES) turbulence model with subgrid turbulent kinetic energy closure. Combustion was modeled using a strained laminar flamelet library approach. Radiative heat transfer was accounted for with a model utilizing the gray-gas approximation. In the present study, additional validation analysis is performed using the area validation metric (AVM). These activities are done on multiple datasets involving different variables and temporal/spatial ranges and intervals. In conclusion, the results provide insight into the use of the area validation metric on such temporally varying datasets and the importance of physics-aware use of the metric for proper analysis.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2025

Oklo Sponsored Testing using PELICAN: System, Subchannel, and High-Fidelity Software Validation (Final CRADA Report)

Argonne National Laboratory (the Contractor), located in Lemont IL, and Oklo, Inc., (the Participant), headquartered in Santa Clara, CA, propose to enter into a Cooperative Research and Development Agreement (CRADA) to perform a gap analysis of thermal hydraulic data, perform prototypical fuel assembly pressure drop and cavitation model validation, generate the experimental data as well as the corresponding uncertainties for this matrix and, finally, develop the validation models with the Argonne system level code SAS4A/SASSYS-1, the Argonne subchannel analysis code DASSH, the Argonne high fidelity code Nek5000, and/or the Idaho National Laboratory code Pronghorn Subchannel. The work outlined below will significantly improve the experimental and validation database currently available for liquid metal fast reactors, thus making it a viable part of a comprehensive reactor design and licensing suite to be used by the participant.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Computational modeling and validation of a modified Marple cascade impactor

Oak Ridge National Laboratory (ORNL) is investigating respirable aerosol fractions from failed high-burnup (HBU) commercial spent nuclear fuel (CSNF) rods (Montgomery et al., 2022). The work aims to characterize the source term of radioactive aerosols that could result from mechanical failure and handling of failed fuel rods during storage and/or transportation. The experiment involves capturing and characterizing aerosols from a four-point bending experiment of fueled rod segments at ORNL’s Irradiated Fuels Examination Laboratory (IFEL). For this, a Marple cascade impactor (Series 290) with the ability to collect particles up to aerodynamic equivalent diameters of ~15 μm was tested for feasibility. The commercially available Marple cascade impactor design was modified for the experiment, where the cascade inlet was replaced with a 3D printed inlet nozzle. Collection efficiency curves were then generated with the modified impactor, and the cascade’s performance was tested using ISO dust capture experiments followed by SEM analysis of the collection and computational modeling. The current work highlights the performance testing and experimental validation of this modified Marple Impactor for spent nuclear fuel aerosol collection.

Kumar, Vineet↗
DOE OSTI2023

Model Based Validation of Intelligent Powertrain Strategies for Connected and Automated Vehicles

Systems incorporating Vehicle to Everything (V2X) and conventional cellular based communication in vehicles can significantly help improve energy consumption via a combination of intelligent powertrain control strategies, smarter routing algorithms and driving in such a way as to minimize fuel economy and the emission of carbon dioxide, known as "eco-driving." In projects led by the Southwest Research Institute (SwRI), large-scale traffic simulations are created to model real-world scenarios with dynamic behavior that is reactive to imposed changes. Coupled with high fidelity powertrain models, the closed loop framework enables research and development of such Connected and Automated Vehicle (CAV) enabled technologies at scale. This paper will discuss a traffic system simulation environment that was built based on the High Street urban corridor in Columbus, Ohio. Eco-driving strategies were tested at scale on a variety of powertrain platforms – internal combustion engines, hybrid electric and fully electric vehicles. Furthermore, the paper will focus on hybrid electric powertrain modeling along with details on how the powertrain model was leveraged to develop a sophisticated clustering scheme to help down-select speed traces from large scale simulation studies for validation on vehicle dynamometer. Nominal energy consumption improvement around 12% was observed with good match between simulation studies and vehicle testing.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Cross-scale intercomparison of climate change impacts simulated by regional and global hydrological models in eleven large river basins

Ideally, the results from models operating at different scales should agree in trend direction and magnitude of impacts under climate change. However, this implies that the sensitivity of impact models designed for either scale to climate variability and change is comparable. In this study, we compare hydrological changes simulated by 9 global and 9 regional hydrological models (HM) for 11 large river basins in all continents under reference and scenario conditions. The foci are on model validation runs, sensitivity of annual discharge to climate variability in the reference period, and sensitivity of the long-term average monthly seasonal dynamics to climate change. One major result is that the global models, mostly not calibrated against observations, often show a considerable bias in mean monthly discharge, whereas regional models show a much better reproduction of reference conditions. However, the sensitivity of two HM ensembles to climate variability is in general similar. The simulated climate change impacts in terms of long-term average monthly dynamics evaluated for HM ensemble medians and spreads show that the medians are to a certain extent comparable in some cases with distinct differences in others, and the spreads related to global models are mostly notably larger. Summarizing, this implies that global HMs are useful tools when looking at large-scale impacts of climate change and variability, but whenever impacts for a specific river basin or region are of interest, e.g. for complex water management applications, the regional-scale models validated against observed discharge should be used.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Highlighting the Impact of Yaw Control by Parsing Atmospheric Conditions Based on Total Variation: Preprint

Identification of atmospheric conditions within a multivariate atmospheric dataset is a necessary step in the validation of wind plant control strategies. Most often, operating conditions are characterized in terms of aggregated observations and assume that the atmosphere is 'quasi-steady'. Aggregation of observations without regard to covariance between time series discounts the dynamical nature of the atmosphere and is not sufficiently representative of wind plant operating conditions. Identification and characterization of continuous time periods with atmospheric conditions that have a high value for analysis or simulation sets the stage for more advanced model validation and the development of real-time control and operation strategies. Controlling observational data for statistical stationarity highlights significant enhancements to the power production of waked turbines under wake steering wind plant control. Considering the combined energy ratio of the turbine to which yaw offsets are prescribed as well as the waked turbine show only moderate improvements when filtering for total validation. The same quality control that highlights wake steering also serves to underpin the off-nominal operation of the controlled turbine.

17 WIND ENERGY↗
DOE OSTI2017

Experimental validation and model development for thermal transmittances of porous window screens and horizontal louvred blind systems

Virtually every home in the US has some form of shades, blinds, drapes, or other window attachment, but few have been designed for energy savings. In order to provide a common basis of comparison for thermal performance it is important to have validated simulation tools. This study outlines a review and validation of the ISO 15099 centre-of-glass thermal transmittance correlations for naturally ventilated cavities through measurement and detailed simulations. The focus is on the impacts of room-side ventilated cavities, such as those found with solar screens and horizontal louvred blinds. The thermal transmittance of these systems is measured experimentally, simulated using computational fluid dynamics analysis, and simulated utilizing simplified correlations from ISO 15099. Finally, correlation coefficients are proposed for the ISO 15099 algorithm that reduces the mean error between measured and simulated heat flux for typical solar screens from 16% to 3.5% and from 13% to 1% for horizontal blinds.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

A framework for strategic discovery of credible neural network surrogate models under uncertainty

The widespread integration of deep neural networks in developing data-driven surrogate models for high-fidelity simulations of complex physical systems highlights the critical necessity for robust uncertainty quantification techniques and credibility assessment methodologies, ensuring the reliable deployment of surrogate models in consequential decision-making. Here, this study presents the Occam Plausibility Algorithm for surrogate models (OPAL-surrogate), providing a systematic framework to uncover predictive neural network-based surrogate models within the large space of potential models, including various neural network classes and choices of architecture and hyperparameters. The framework is grounded in hierarchical Bayesian inferences and employs model validation tests to evaluate the credibility and prediction reliability of the surrogate models under uncertainty. Leveraging these principles, OPAL-surrogate introduces a systematic and efficient strategy for balancing the trade-off between model complexity, accuracy, and prediction uncertainty. The effectiveness of OPAL-surrogate is demonstrated through two modeling problems, including the deformation of porous materials for building insulation and turbulent combustion flow for ablation of solid fuels within hybrid rocket motors.

42 ENGINEERING↗
DOE OSTI2026

DEM Modeling and Validation of Pebble Bed Packing Using Chrono::GPU

Accurate prediction of pebble packing structure is important for pebble bed reactors because the spatial distribution of void fraction directly affects coolant flow, pressure drop, heat transfer, and neutronic behavior. However, experimentally validated DEM studies that directly evaluate local void-fraction structure in reactor-relevant pebble beds remain limited. In this work, the pebble bed experiment conducted at Missouri University of Science and Technology is simulated using the graphics processing unit (GPU)-based discrete element method (DEM) code Chrono::GPU. The study focuses on evaluating the ability of Chrono::GPU to reproduce the packing arrangement and void-fraction distribution of a randomly packed spherical pebble bed. The DEM results are first verified against established radial void-fraction correlations, including the Mueller and Vortmeyer-Schuster models, to assess the predicted bulk porosity, near-wall behavior, and oscillatory packing structure. The simulation is then verified against reference DEM data and validated against gamma-ray computed tomography (CT) experimental data at three axial locations. The Chrono::GPU results reproduce the main features of the experimental packing, including the high void fraction near the wall, the first near-wall trough, and the damped oscillatory radial profile caused by wall-induced ordering. Quantitative comparison with DEM data and the CT-based radial profiles shows good agreement, with mean absolute errors on the order of 0.07 and root-mean-square errors below 0.09 for the averaged profiles. These results demonstrate that Chrono::GPU can accurately capture the void-fraction structure of spherical pebble beds and provides a reliable DEM framework for future pebble bed reactor packing, recycling, and thermal-hydraulic studies.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Experimentally Validated Numerical Models of Non-Isothermal Turbulent Mixing in High Temperature Reactors

In the Very High Temperature Reactor (VHTR), the non-uniform heat generation and flow maldistribution of coolant in the core generates conditions leading into the lower plenum with many jets at different temperatures and velocities. The hope is that the combined flow becomes fully mixed in a short distance so that the fluctuating temperatures in the mixing region do not cause unwanted thermal stresses in the supporting structures. These cyclic thermal stresses can cause degradation of the wall microstructure including crack initiation and growth, ultimately leading to the fatigue failure in the lower plenum, and can be accelerated by the high temperature environment in the VHTR. The focus of this project was to provide experimental data for future validation of computational efforts aimed at capturing the turbulent mixing in the lower plenum. Computational fluid dynamics (CFD) is also used as part of this effort to assess the requirements to model fundamental flows with application to the lower plenum as well at the applied flow conditions that mimic the experimental facilities. These efforts will lay the groundwork for future incorporation of stress analysis as well as fatigue and failure studies for multiple VHTR components. An additional emphasis is placed on reduced order models (ROM) using canonical flows, which will help to balance computational expense and accuracy and enable future work in uncertainty quantification. The flow in the lower plenum is extremely complex with hundreds of cooling jets entering and then being forced to change directions by 90° while navigating through an array of cylindrical support posts. Generating experimental data for such a complicated flow is difficult, not to mention that the computational requirements to generate an adequate temporal and spatial sampling is extremely expensive and time consuming. Therefore, the ultimate focus of this research is a “unit cell” which consists of six jets in the presence of a crossflow, and seven cylindrical support posts. It is scaled to achieve similar ranges of key dimensionless numbers. This serves to mimic flow conditions in different regions of the lower plenum by adjusting velocities, temperatures, and orientations, and represents a compromise between the complexity inside the full-scale application and the ideal conditions of a more fundamental study. In addition to the unit cell experiments and simulations, the complex flows in the VHTR lower plenum are broken down into a number of simplified (in some cases even fundamental) flows, two of which are turbulent jets and flow past cylinders. Each of these are studied, computationally and experimentally for isothermal and non-isothermal conditions. Flows where trusted experimental data is available in the literature (e.g., turbulent free jet), additional experiments are not needed. The result of these efforts is a database of experimental data and multiple computational studies, which provide an outlook to the requirements, needed to capture turbulent mixing flow physics The ROM results provide assessments for appropriate resource-light models that balance accuracy with reduced computational burdens.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Structural modeling and validation of laminated stacks in magnetic gearing applications

Laminated structures are commonly employed in magnetic gears based on their ability to direct magnetic flux, while inhibiting eddy currents. Unfortunately, the stiffness of the laminated structure is much lower than a solid part, which can lead to unacceptable deflections, given the large magnetic forces and small air gaps in magnetic gears. Finite element analysis of laminations to accurately predict these deflections can be computationally expensive due to the small elements needed to model the thin lamination dimensions. These analyses also have some uncertainty due to the assignment of bonding stiffness. This paper presents a means of accurately modelling the deflection of a laminated stack with reduced complexity and computational time, which is compared to experimental results. Here, the resulting methods are then used to assess the magnetic and mechanical advantages of different designs for the modulating pieces of a magnetic gear.

42 ENGINEERING↗