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NASA NTRS2001

The Role of Convection and Growth Competition in Phase Selection in Microgravity: Controlled Convection in the Containerless Processing of Steel Alloys

Containerless processing using electromagnetic levitation (EML) is a powerful technique in the investigation of reactive molten metal systems. On ground, the power required to overcome the weight of the sample is sufficient to cause significant heating and induce substantial melt convection. In microgravity, the heating and positioning fields may be decoupled and the field strength may be varied to achieve the desired level of convection within the limits set by the geometry of the levitation coil and the sample size. From high-speed digital images of the double recalescence behavior of Fe-Cr-Ni alloys in ground-based testing and in reduced-gravity aboard the NASA KC-135 parabolic aircraft, we have shown that phase selection can be predicted based on a growth competition model. An important parameter in this model is the delay time between primary nucleation and subsequent nucleation of the stable solid within the liquid/metastable solid array. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the first Microgravity Sciences Laboratory (MSL-1) mission, we also know that convection may significantly influence the delay time, especially at low undercoolings. Currently, it is unclear what mechanism controls the formation of a heterogeneous site that allows nucleation of the austenitic phase on the pre-existing ferrite skeleton. By examining the behavior of the delay time under different convective conditions, we hypothesize that we can differentiate between several of these mechanisms to gain an understanding of how to control microstructural. evolution. We will anchor these predictions by examining samples quenched at different times following primary recalescence in microgravity. A second important parameter in the growth competition model is the identification of the growth rate of the stable phase into the semi-solid array that formed during primary recalescence. Current dendritic growth theory is inadequate in predicting solidification behavior under these conditions as metallographic analyses show that stable phase growth proceeds along the interface between the metastable solid and residual liquid. Since growth velocity is independent of the initial undercooling relative to the metastable liquidus, we hypothesize that purely thermal effects can be separated from other important growth model parameters by careful selection of the liquid composition in a ternary system.

Matson, D. M.↗

NASA NTRS1975

Study on processing immiscible materials in zero gravity

An experimental investigation was conducted to evaluate mixing immiscible metal combinations under several process conditions. Under one-gravity, these included thermal processing, thermal plus electromagnetic mixing, and thermal plus acoustic mixing. The same process methods were applied during free fall on the MSFC drop tower facility. The design is included of drop tower apparatus to provide the electromagnetic and acoustic mixing equipment, and a thermal model was prepared to design the specimen and cooling procedure. Materials systems studied were Ca-La, Cd-Ga and Al-Bi; evaluation of the processed samples included the morphology and electronic property measurements. The morphology was developed using optical and scanning electron microscopy and microprobe analyses. Electronic property characterization of the superconducting transition temperatures were made using an impedance change-tuned coil method.

Reger, J. L.↗

NASA NTRS1990

High pressure superconducting radial magnetic bearing

In a conventional radial magnetic bearing, the rotor (soft magnetic material) can only have attraction force from one of the electromagnets in the stator. The stator electromagnets consist of small copper windings with a soft magnetic material iron yoke. The maximum pressure obtainable is about 200 N/sq cm. It is shown that replacing the stator copper winding by a superconducting winding in the above configuration can increase the pressure to about 1000 N/sq cm. It is also shown that replacing the iron in the rotor by a group of superconducting windings in persistent mode and using a group of saddle coils in the stator can produce a pressure in excess of 2000 N/sq cm.

Eyssa, Y. M.↗

NASA NTRS1974

Feasibility study of a swept frequency electromagnetic probe (SWEEP) using inductive coupling for the determination of subsurface conductivity of the earth and water prospecting in arid regions

Techniques developed for electromagnetic probing of the lunar interior, and techniques developed for the generation of high power audio frequencies were combined to make practical a magnetic inductive coupling system for the rapid measurement of ground conductivity profiles which are helpful when prospecting for the presence and quality of subsurface water. A system which involves the measurement of the direction, intensity, and time phase of the magnetic field observed near the surface of the earth at a distance from a horizontal coil energized so as to create a field that penetrates the earth was designed and studied to deduce the conductivity and stratification of the subsurface. Theoretical studies and a rudimentary experiment in an arid region showed that the approach is conceptually valid and that this geophysical prospecting technique can be developed for the economical exploration of subterranean water resources.

Latorraca, G. A.↗

NASA NTRS2003

Three-Dimensional Magnetic Analysis Technique Developed for Evaluating Stirling Convertor Linear Alternators

The Department of Energy, the Stirling Technology Company (STC), and the NASA Glenn Research Center are developing Stirling convertors for Stirling radioisotope generators to provide electrical power for future NASA deep space missions. STC is developing the 55-We technology demonstration convertor (TDC) under contract to the Department of Energy. The Department of Energy recently named Lockheed Martin as the system integration contractor for the Stirling radioisotope generator development project. Lockheed Martin will develop the Stirling radioisotope generator engineering unit and has contract options to develop the qualification unit and the first flight unit. Glenn s role includes an in-house project to provide convertor, component, and materials testing and evaluation in support of the overall power system development. As a part of this work, Glenn has established an in-house Stirling research laboratory for testing, analyzing, and evaluating Stirling machines. STC has built four 55-We convertors for NASA, and these are being tested at Glenn. A cross-sectional view of the 55-We TDC is shown in the figure. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. In support, Glenn has been developing finite element analysis and finite element method tools for performing various linear alternator thermal and electromagnetic analyses and evaluating design configurations. A three-dimensional magnetostatic finite element model of STC's 55-We TDC linear alternator was developed to evaluate the demagnetization fields affecting the alternator magnets. Since the actual linear alternator hardware is symmetric to the quarter section about the axis of motion, only a quarter section of the alternator was modeled. The components modeled included the mover laminations, the neodymium-iron-boron magnets, the stator laminations, and the copper coils. The three-dimensional magnetostatic model was then coupled with a circuit simulator model of the alternator load and convertor controller. The coupled model was then used to generate alternator terminal voltage and current predictions. The predicted voltage and current waveforms agreed well with the experimental data, which tended to validate the accuracy of the coupled model. The model was then used to generate predictions of the demagnetization fields acting on the alternator magnets for the alternator under load. The preliminary model predictions indicate that the highest potential for demagnetization is along the inside surface of the uncovered magnets. The demagnetization field for the uncovered magnets when the mover is positioned at the end of a stroke is higher than it is when the mover is at the position of maximum induced voltage or maximum alternator current. Assuming normal load conditions, the model predicted that the onset of demagnetization is most likely to occur for magnet temperatures above 101 C.

Geng, Steven M.↗

NASA NTRS1976

Solar energy trap

An apparatus is described for trapping solar energy for heating a fluid that could be subsequently used in turbines and similar devices. The apparatus includes an elongated vertical light pipe having an open end through which the visible spectrum of electromagnetic radiation from the sun passes to strike a tubular absorber. The light pipe has a coated interior surface of a low absorptivity and a high reflectivity at the visible wavelengths and a high absorptivity/emissivity ratio at infrared wavelengths. The tubular absorber has a coating on the surface for absorbing visible wavelengths to heat the fluid passing through. Infrared wave lengths are radiated from the tubular absorber back into the light pipe for heating fluid passing through a tubular coil wound around it.

Brantley, L. W., Jr.↗

NASA NTRS1984

Superconducting electromagnets for large wind tunnel magnetic suspension and balance systems

A superconducting electromagnetic suspension and balance system for an 8 x 8-ft, Mach 0.9 wind tunnel is presented. The system uses a superconducting solenoid as a model core 70 cm long and with a 11.5 cm OD, and a combination of permanent magnet material in the model wings to produce the required roll torque. The design, which uses an integral cold structure rather than separate cryostats for mounting all control magnets, has 14 external magnets, including 4 racetrack-shaped roll coils. Helium capacity of the system is 3.0 to 3.5 l with idling boiloff rate predicted at 0.147 to 0.2 l/h. The improvements yielded a 50-percent reduction in the system size, weight, and cost.

Boom, R. W.↗

DOE OSTI2024

Design Optimization and Measurement Uncertainty of an Electromagnetic Level Sensor for Liquid Metal Reactors

Here, this article describes the design and operation of a prototype mutual inductance level sensor (MILS) and the development and validation of a finite-element analysis (FEA) model describing its behavior. The MILS was designed for use in liquid sodium up to temperatures of 650 °C in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). Preliminary testing was performed in a room temperature test stand with aluminum acting as an analog for the sodium to better understand sensor performance and provide accurate code validation data. This experimental data, along with material properties found in literature, were used to validate an FEA model in ANSYS Maxwell. The validated ANSYS Maxwell model was used to examine the performance of the MILS in various environments and under various operating conditions. Simulations suggest the following: The MILS will perform adequately in liquid sodium and liquid lead at temperatures up to 650 °C . The temperature dependence of electrical conductivity imposes a temperature dependence on the sensor that requires proper compensation. The MILS signal sensitivity is maximized when mutual inductance between sensor coils is maximized, and sensor geometry should be selected to account for this factor. The operating frequency of the MILS can be optimized and is dependent on process fluid material, operating temperature, and materials/geometry of sensor system. Finally, the use of a stainless-steel isolating thimble does not adversely affect the sensor signal. The primary sources of error for this MILS system are the accuracy of the calibration standard against which the sensor is calibrated, and the temperature dependence of the sensor. This work contains all the necessary details to recreate the FEA model and results. This model can be used to optimize the performance of a MILS in any operating environment to read any electrically conductive working fluid.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2021

Computation of the Biot–Savart line integral with higher-order convergence using straight segments

One common approach to computing the magnetic field produced by a filamentary current-carrying coil is to approximate the coil as a series of straight segments. The Biot–Savart field from each straight segment is analytically known. However, if the endpoints of the straight segments are chosen to lie on the coil, then the accuracy of the Biot–Savart computation is generally only the second order in the number of endpoints. In this work, we propose a simple modification: shift each end point of the coil in the outward normal direction by an amount proportional to the local curvature. With this modification, the Biot–Savart accuracy increases to the fourth order and the numerical error is dramatically reduced for a given number of discretization points.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Magnetic Shield Design for the Double-D Coil-Based Wireless Charging System

In this work, magnetic field emission (MFE) of the high-power double-D (DD) coil-based wireless charging system is investigated and a shielding technique is proposed. The MFE pattern produced by the DD coils is significantly different from the MFE of the unipolar (e.g., circular, square, or rectangular) coils, and the traditional aluminum shield does not suppress the MFE from the DD coils. This study shows that a conventional aluminum shield increases the MFE, and a magnetic shield effectively suppresses the MFE of the DD coils. Therefore, a magnetic shield consisting of high-permeability magnetic material, such as ferrites, nanocrystalline, etc., is proposed for the DD pads. The shielding effectiveness of the proposed shield is evaluated through finite element analysis and verified through experiments. An 11 kW DD coil-based wireless charging system was used to test the proposed shielding technique. The experimental results show that a traditional aluminum shield increased the MFE by 29.8%, and the proposed magnetic shield suppressed the MFE by 50.5%.

42 ENGINEERING↗

NASA NTRS1961

Theory of an Electromagnetic Mass Accelerator for Achieving Hypervelocities

It is shown that for any electromagnetic accelerator which employs an electromagnetic force for driving the projectile and uses the projectile as the heat sink for the energy dissipated in it by ohmic heating, the maximum velocity attainable without melting is a function of the mass of the projectile. Therefore, for hypervelocities a large projectile mass is required and thus a power supply of very large capacity is necessary. It is shown that the only means for reducing the power requirement is maximizing the gradient of the mutual inductance. In the scheme of the sliding-coil accelerator investigated herein, the gradient of the mutual inductance is continuously maintained at a high value. It is also shown that for minimum length of the accelerator, the current must be kept constant despite the rise in induced voltage during acceleration. The use of a capacitor bank as an energy source with the condition that the current be kept constant is investigated. Experiments at low velocities are described.

Thom, Karlheinz↗

DOE OSTI2022

Fully Distributed Multi-Material Magnetic Sensing Structures for Multiparameter DAS Applications

This dissertation demonstrates the first of its kind distributed magnetic field sensor based on a fiber optic distributed acoustic sensing (DAS) scheme. Ferromagnetic nickel and Metglas® were dispersed internally within a fiber optic preform and then drawn on an in-house fiber optic draw tower to lengths in the kilometers. Due to the close proximity of the ferromagnetic metals and fiber optic core, the magnetostrictive strain response of the ferromagnetic materials when exposed to a magnetic field would perturbate within the fiber cladding and transfer that strain, internally, to the fiber optic core. Strain resulting from the magnetostrictive effect allows the DAS based sensor to accurately translate strain into readable magnetic field data. Due to the high sensitivity seen in this sensor design, multiparameter sources, acoustic and magnetic fields, were tested and validated and a three dimensional magnetic-field vector sensor was proposed. Numerical analysis of the novel sensor design was first implemented using COMSOL Multiphysics, where inputs such as magnetostrictive element shape, size, distance, and number were first investigated. Upon optimizing system constraints, the sensor design was further modified such that single mode operation was consistent across multiple fiber draws while retaining high strain transfer from the ferromagnetic elements to the fiber optic core. Ferromagnetic material selection was evaluated as a function of the saturation magnetostriction constants and a total of 4 modules were used to fully characterize the complex physics involved in this sensor design. All fabrication and testing were performed in-house using a full scale 3-story fiber draw tower and custom environmental testing stations to imitate naturally occurring events such as magnetic or acoustic point sources. A unique stacking method was used to embed ferromagnetic nickel and Metglas® into a fiber optic preform which when combined with a custom fiber draw process resulted in consistent multi-material fibers drawn to lengths of 1-km. In-house testing facilities included different types of electromagnetic generators, in addition to a soil test bed, and an outdoor test bed which allowed 100 meters of fiber to be tested simultaneously. All tested sensors demonstrated high strain transfer capabilities on the order of 0.01-10 μϵ depending on the materials used, ferromagnetic rod number, and core to metal spacing. Due to the sensitivity of the system the difference between AC and DC was distinct, and directional magnetostriction was studied. Transverse and longitudinal magnetic wave propagation was controlled through a solenoid and rectangular Helmholtz coil, both built in-house. A three-dimensional magnetic field vector sensor was proposed due to the success of the magnetic field sensor, and a design was proposed and initially tested to validate direction as a function of field strength and distance. To summarize, this dissertation explores the first fully distributed magnetic field sensor using DAS based techniques and one of the first multi-material fiber draw processes which can produce consistent single mode fiber up to 1-km. Due to extensive FEA modeling, multiple iterations of the magnetic sensor were fully characterized and an equation describing the relationship between sensor design and strain transfer has been created and validated experimentally. Multi-parameter tests including acoustic and magnetic fields were implemented and an algorithm was developed to separate the mixed signals. Finally, a test was performed to demonstrate the feasibility of sensing magnetic fields directionally. Cumulative results demonstrate a high-quality sensor alternative to current designs which may surpass other magnetic sensors due to innate multi-parameter capabilities, in addition to the inexpensive production cost and extremely long operating lengths.

02 PETROLEUM↗

NASA NTRSDate not supplied

Continued Development of the Pulsed Magnetic Nozzle for the Pulsed Fission Fusion (PuFF) Vehicle

High thrust, high specific impulse propulsion systems, such as PuFF (Pulsed Fission-Fusion)offer a new paradigm of speed and safety when exploring the solar system. To realize thesepossibilites, PuFF needs a mature magnetic nozzle design. PuFF’s magnetic nozzle is uniquein that it must provide power in addition to thrust. In the authors’ opinion, the power systemdesign is fairly mature, but nozzle thrust coil design is less so. Previous work has suggested thatthe PuFF magnetic nozzle will behave similarly to a ‘magnetic reflection chamber,’ relying onprinciples of magnetic flux compression to re-direct nozzle flow. However, recent work, usingthe 3D modeling software SPFMax, suggests that plasma motion in the nozzle will be drivenby the Lorentz force. This recent work is limited in that the plasma did not completely leavethe nozzle before the simulation ended. In this work, we aim to extend the SPFMax modelfrom previous work, with a bolstered electromagnetic field solver, so the model can run untilthe plasma is fully evacuated. We hope to confirm previous results regarding the ideal PuFFnozzle design, but we could be surprised. Through improving the PuFF nozzle model, weaim to reduce technical risk with building the nozzle, realize paradigm-shifting performancenumbers, and allow rapid, reliable, and safe exploration of the solar system.

Nathan M Schilling↗

DOE OSTI2024

Preliminary Design of Ironless Linear Induction Motors for ITER MSE Shutter Actuators

In this article, the shutters need to be closed or opened during the operation and calibration period time for the fusion diagnostic systems, such as the International Thermonuclear Experimental Reactor (ITER) motional stark effect (MSE). Standard electric motors and actuators will not work in a strong magnetic field environment due to the presence of the magnetic field of fusion reactors. The innovative linear induction motor (LIM) with an ironless feature overcomes this kind of challenge and can be used for any application that requires controlled motion with a large stroke in the magnetic field environment. It consists of a high-electrical conductivity plate like copper and three-phase motor windings with nonferrous or stainless-steel stators. The conductor plate attached with the shutter is simply driven by the underneath three-phase linear windings to achieve linear motion. The motor drive can be controlled remotely by a controller using the electrical connection, so no sensitive electronic components are located in the harsh environment where the motor itself is located. The design requirements and test facility have been described. Several 3-D transient Maxwell electromagnetic (EM) models with different locations of three-phase linear motor windings and shutter stators have been analyzed and evolved to meet any applications allowed in the harsh environment inside the vacuum vessel of fusion reactors. The preliminary design results are presented in this article.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Design of passive and structural conductors for tokamaks using thin-wall eddy current modeling

Abstract A new three-dimensional electromagnetic modeling tool ( ThinCurr ) has been developed using the existing PSI-Tet finite-element code in support of conducting structure design work for both the SPARC and DIII-D tokamaks. Within this framework a 3D conducting structure model was created for both the SPARC and DIII-D tokamaks in the thin-wall limit. This model includes accurate details of the vacuum vessel and other conducting structural elements with realistic material resistivities. This model was leveraged to support the design of a passive runaway electron mitigation coil (REMC), studying the effect of various design parameters, including coil resistivity, current quench duration, and plasma vertical position, on the effectiveness of the coil. The REMC is a non-axisymmetric coil designed to passively drive large non-axisymmetric fields during the plasma disruption thereby destroying flux surfaces and deconfining RE seed populations. These studies indicate that current designs should apply substantial 3D fields at the plasma surface during future plasma current disruptions as well as highlight the importance of having the REMC conductors away from the machine midplane in order to ensure they are robust to off-normal disruption scenarios.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1974

Evaluation of selected strapdown inertial instruments and pulse torque loops, volume 1

Design, operational and performance variations between ternary, binary and forced-binary pulse torque loops are presented. A fill-in binary loop which combines the constant power advantage of binary with the low sampling error of ternary is also discussed. The effects of different output-axis supports on the performance of a single-degree-of-freedom, floated gyroscope under a strapdown environment are illustrated. Three types of output-axis supports are discussed: pivot-dithered jewel, ball bearing and electromagnetic. A test evaluation on a Kearfott 2544 single-degree-of-freedom, strapdown gyroscope operating with a pulse torque loop, under constant rates and angular oscillatory inputs is described and the results presented. Contributions of the gyroscope's torque generator and the torque-to-balance electronics on scale factor variation with rate are illustrated for a SDF 18 IRIG Mod-B strapdown gyroscope operating with various pulse rebalance loops. Also discussed are methods of reducing this scale factor variation with rate by adjusting the tuning network which shunts the torque coil. A simplified analysis illustrating the principles of operation of the Teledyne two-degree-of-freedom, elastically-supported, tuned gyroscope and the results of a static and constant rate test evaluation of that instrument are presented.

Sinkiewicz, J. S.↗

DOE OSTI2026

Novel and Rugged Electromagnetic Wireless System for Long-Term Subsurface CO₂ Plume Monitoring and Saturation Mapping

Novel and rugged electromagnetic wireless system for long-term subsurface CO₂ plume monitoring and saturation mapping is a Phase I SBIR project led by Cyentech Consulting LLC to develop a permanently installed, outside-casing electromagnetic monitoring system for long-term carbon storage monitoring. The project addresses a major challenge in carbon capture and storage: the need for reliable, cable-free downhole monitoring that can detect CO₂ plume movement and saturation changes without compromising well integrity through casing perforations or external umbilical cables.

58 GEOSCIENCES↗

NASA NTRS1991

Containerless processing and rapid solidification of Nb-Si alloys of hypereutectic composition

A combination of bulk undercooling in an electromagnetic levitation apparatus and splat quenching between two copper plates is used to process Nb-Si alloys in order to maximize rapid solidification conditions and minimize the effects of recalescence, with emphasis on the solidification of characteristics of alloys in the 21 to 27 at. pct Si range of composition. SEM and TEM as well as X-ray diffraction are used to characterize the microstructures of the processed samples. In the range of compositions studied, the splat-quenched drops always formed the tetragonal Nb3Si phase directly from the liquid. Drops solidified in the coil were characterized by the presence of the primary intermetallic Nb5Si3 and the absence of both peritectic Nb3Si and the equilibrium eutectic. In these cases, a metastable alpha-Nb + beta-Nb5Si3 eutectic formed. The results are discussed in terms of possible metastable configurations of the Nb-Si phase diagram as well as concepts of nucleation and growth kinetics applied to the Nb3Si and Nb5Si3 intermetallics.

Hofmeister, W. H.↗