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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design and construction of the MUSE permanent magnet stellarator

This paper documents the design and construction of MUSE, the world's first permanent magnet (PM) stellarator and the first quasi-axisymmetric experiment. The purpose of MUSE is to develop and assess a new way of building optimised stellarators that uses simple planar coils PMs. Our PM optimisation algorithm consists of initialising a geometry to pack dipoles densely, running the FAMUS code to minimise surface field error subject to PM constraints and applying discrete jumps to reach a physically realisable solution. FAMUS treats the PM system as a set of ideal point dipoles. From there we construct finite-volume magnet towers to be housed in 3D-printed PM holders. We describe the design of the PM holders, which were validated by laser metrology. We analyse the effects of finite permeability, sensitivity to perturbations and magnetostatic forces. An exact analytic formula for the magnetic field from a finite-volume PM tower is presented to compute PM–PM forces and stress on the PM holder. Stellarator construction is complete and experiments are underway.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Thermal stability of anisotropic bonded magnets prepared by additive manufacturing

Abstract In this research, anisotropic NdFeB + SmFeN hybrid and NdFeB bonded magnets are additively printed in a polyphenylene sulfide (PPS) polymer binder. Printed NdFeB + SmFeN PPS bonded magnets displayed excellent magnetic properties ( B r [remanence] = 6.9 kG [0.69 T], H cj [coercivity] = 8.3 kOe [660 kA/m], and BH max [energy product] = 9.9 MGOe [79 kJ/m 3 ]) with superior corrosion resistance and thermal stability. The anisotropic NdFeB bonded magnet shows a high coercivity of 14.6 kOe (1162 kA/m) with a BH max of 8.7 MGOe (69 kJ/m 3 ). The coercivity and remanence temperature coefficients for NdFeB + SmFeN hybrid bonded magnets are −0.10%/K and −0.46%/K, and for NdFeB bonded magnets are −0.14%/K and −0.53%/K in the range of 300–400 K, indicating that the hybrid bonded magnets are thermally stable. The average flux aging loss for hybrid magnets was also determined to be very stable over 2000 h at 448 K (175°C) in air with 2.04% compared to that of NdFeB magnets with 3.62%.

thermal stability↗
DOE OSTI2023

How do magnetized HED flows transition to collimated plasma jets? (Final Report)

We present results from a pulsed-power experiment designed to generate accretion-like flows in the laboratory that may be used to study the dynamics of astrophysical accretion-driven outflows. To emulate systems like Young Stellar Object (YSO) outflows, we create radially converging plasma flows in a short disk that transition into much longer bipolar outflows. Our experiment uses a ~1 MA pulsed-power driver to generate plasma from an array of thin aluminum wires mounted to a 3D-printed current path that controls the angular momentum and magnetic field topology. In this paper, we show that experimental data scale favorably to observed properties of YSO jets. This set of experiments tests the simplest version of our possible plasma dynamics, where outflows are generated without rotation or axial magnetic field present. The temperature, velocity and density of the disk and outflows are characterized using interferometry, gated optical and ultraviolet imaging, and Thomson scattering diagnostics. We discuss the Reynolds number, magnetic Reynolds number and Mach numbers calculated in three different stages of the experiment, and compare our results to 3D numerical simulations in the PERSEUS magnetohydrodynamics code. This report is a summary of the work done by the graduate students who were supported by the project.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Integral Field Probe for Mapping of Curved Magnets

The Single Stretched Wire (SSW) method allows highly precise integral field measurements by recording voltage across a tensioned wire mounted to 2-axis linear stages at either end of the magnet aperture. However, traditional SSW probes are not well suited for curved accelerator magnets, which are essential for steering charged particles along arced trajectories in storage rings or beamlines. The tension required to eliminate sag demands a purely straight path, making them incompatible with non-linear magnet geometries. To address this limitation for curved magnets, a modified approach was developed using a segmented, 3D-printed support structure that incorporates a pre-shaped anti-sag curve. Under its own weight and that of the wire bundle, the structure deforms to lie flat while conforming to the curvature of the magnet in the horizontal plane. The optimal geometry of the probe was derived using an iterative process combining FEA simulations in Ansys Mechanical with testing of various carbon fiber-reinforced filaments. The printed and assembled probe was successfully used to measure the SDD-059 magnet at Fermilab, yielding promising results.

Jakopin, Alexander [Northern Illinois U.]↗
DOE OSTI2020

3D Printing Prototypes for a Reflector-Based Broadband Axion Search

This work sought to begin research and development on a horn antenna which can be used to transfer the energy of microwave photons produced by axions in a strong magnetic field to a coaxial cable for measurement. 3D prototypes of pyramidal horn antennas and a parabolic reflector were printed and then coated with conductive spray paint. The S 11 parameter was measured and simulated for both 3D printed horn antenna and the conical horn antenna both with and without the reflector present to determine how much of the radiated power was reflected back. Ultimately, for both the conical and pyramidal antennas, less than one percent of the energy emitted by the antennas was reflected back. When the pyramidal antenna was tilted by about 45 degrees, however, around 30-40 percent of the microwaves emitted by the antennas was reflected back.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Using additive manufacturing technologies in high-field accelerator magnet coils

Recent advances with additive manufacturing (AM) technologies using various materials allow them to be considered for the manufacture of precise and complicated metal parts of the magnet coils of high field accelerator magnets from aluminum bronze, titanium alloy, stainless steel, etc. The 3D printing technology is also being used to fabricate prototype models of real parts to test and optimize their geometry. This paper discusses the designs of the complex stress-management coil parts developed at Fermilab, their fabrication using AM technologies, and quality control methods and results.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Functional soft materials and methods of making and using thereof

Disclosed are functional materials for use in additive manufacturing (AM). The functional material can comprise an elastomeric composition (e.g., a silicone composite) for use in, for example, direct ink writing. The elastomeric composition can include and elastomeric resin, and a magnetic nanorod filler dispersed within the elastomeric resin. Nanorod characteristics (e.g., length, diameter, aspect ratio) can be selected to create 3D-printed constructs with desired mechanical properties along different axes. Furthermore, since nickel nanorods are ferromagnetic, the spatial distribution and orientation of nanorods within the continuous phase can be controlled with an external magnetic field. This level of control over the nanostructure of the material system offers another degree of freedom in the design of functional parts and components with anisotropic properties. Magnetic fields can be used to remotely sense compression of the constructs, or alternatively, control the stiffness of these materials.

Berkland, Cory↗
DOE OSTI2024

Functional soft materials and methods of making and using thereof

Disclosed are functional materials for use in additive manufacturing (AM). The functional material can comprise an elastomeric composition (e.g., a silicone composite) for use in, for example, direct ink writing. The elastomeric composition can include an elastomeric resin, and a magnetic nanorod filler dispersed within the elastomeric resin. Nanorod characteristics (e.g., length, diameter, aspect ratio) can be selected to create 3D-printed constructs with desired mechanical properties along different axes. Furthermore, since nickel nanorods are ferromagnetic, the spatial distribution and orientation of nanorods within the continuous phase can be controlled with an external magnetic field. This level of control over the nanostructure of the material system offers another degree of freedom in the design of functional parts and components with anisotropic properties. Magnetic fields can be used to remotely sense compression of the constructs, or alternatively, control the stiffness of these materials.

Berkland, Cory↗
DOE OSTI2026

Super Conducting REBCO Cable Wrapper

Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.

Gillen, Kameron [Northern Illinois U.]↗
DOE OSTI2023

3-D Printed Electro-Magnetic Objects for THz Communications

Advanced materials and manufacturing techniques will pave the path towards high quality electro-magnetic circuits that operate up through THz and into optics regime. Digital additive manufacturing (AM) techniques offer game-changing potential for large scale manufacturing of Radio-frequency (RF) circuits and system in custom 2D/3D geometries. The technical collaboration will explore the design flexibility and product customization capabilities of additive manufacturing techniques to process magnetic materials in custom 3D geometries with tailored dielectric properties and frequency response characteristics. Transformation of an RF circuit design idea into a 3D printed system using additive manufacturing techniques will bring together the elements of advanced materials, additive integration, and low-cost manufacturing for future advanced wireless communication systems.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Fractional Skyrmion Tubes in Chiral‐Interfaced 3D Magnetic Nanowires

Magnetic skyrmions are chiral spin textures with rich physics and great potential for unconventional computing. Typically, skyrmions form in bulk crystals with reduced symmetry or ultrathin film multilayers involving heavy metals. Here, the formation of fractional Bloch skyrmion tubes at room temperature is demonstrated by 3D printing ferromagnetic double‐helix nanowires with two regions of opposite chirality. Using X‐ray microscopy and micromagnetic simulations, it is shown that the coexistence of vortex and anti‐parallel spin states induces the formation of fractional skyrmion tubes at zero magnetic fields, minimizing the energy cost of breaking the coupling between geometric and magnetic chirality. Control over zero‐field states is also demonstrated, including pure vortex, or mixed skyrmion‐vortex states, highlighting the magnetic reconfigurability of these 3D nanowires. This work shows how interfacing chiral geometries at the nanoscale can enable advanced forms of topological spintronics.

X-ray microscopy↗
DOE OSTI2025

Fermilab Automation of Coil Winding System

The automated coil winder project creates a repeatable, scalable method for producing superconducting magnet coils with increased accuracy and efficiency. The design uses an ortho cyclic winding method to achieve high fill factors by combining computer numerical control (CNC), microcontroller-based controls, and sophisticated optimization techniques. The method optimizes coil turns, core geometry, and current consumption by utilizing analytical models based on magnetic moment, Ohm’s law, and power constraints. For particle accelerator applications, prototype testing using a 3D-printed coil winder has shown enhanced winding repeatability, thermal management, and manufacturability.

Dzida, Rafal [Northern Illinois U.]↗
DOE OSTI2025

Effects of Surface Treatments on the Outgassing of 3D-Printed 316L Stainless Steel.

Fermi National Accelerator Laboratory (Fermilab) is a world leader in designing and operating particle accelerators for nuclear and particle physics research. These accelerators rely on electric fields to propel particle beams, which are then directed and focused using magnetic fields. To ensure these beams travel without interference, they must move through an ultra-high vacuum environment, typically around 10⁻⁹ torr. Maintaining such a vacuum requires materials with exceptionally low outgassing rates. 316L stainless steel is a common material choice for vacuum systems due to its low outgassing rates, excellent corrosion resistance, non-magnetic properties, and high mechanical strength. When manufactured using traditional methods like machining, extrusion, and casting, the vacuum properties of 316L stainless steel are well understood. However, the behavior of 316L stainless steel produced through additive manufacturing, such as Direct Metal Laser Sintering (DMLS), is not as well documented. This study aims to determine the outgassing rate of 316L stainless steel fabricated using DMLS. The investigation focuses on measuring the outgassing rates of 1.5 2 vacuum reducers and evaluating the effects of surface preparation techniques, such as mechanical polishing and electropolishing, on the outgassing performance. Understanding the outgassing performance of 3D-printed 316L stainless steel could enable Fermilab engineers to adopt this fabrication method for producing complex parts designed for ultra-high vacuum environments. These advancements have the potential to benefit projects, such as the Long-Baseline Neutrino Facility (LBNF) and the Proton Improvement Plan-II (PIP-II), by improving design flexibility and fostering innovation in accelerator development.

Cloud, Jaiden [Central State University]↗
DOE OSTI2025

Additively-manufactured monocrystalline YBCO superconductor

Abstract Single-crystal microstructures enable high-performance YBa 2 Cu 3 O 7-x superconductors which are however limited to simple shapes due to their brittleness. Additive manufacturing can fabricate YBa 2 Cu 3 O 7-x superconductor with complex shapes, albeit with a polycrystalline microstructure. Here, we demonstrate a route to grow single-crystals from 3D-ink-printed, polycrystalline, sintered superconducting YBa 2 Cu 3 O 7-x (YBCO or Y123) + Y 2 BaCuO 5 (Y211), manufacturing objects with complex architectures displaying both high critical current density (J c =2.1 × 10 4 A . cm –2 , 77 K) and high critical temperature (T c = 88-89.5 K). An ink containing precursor powders (Y 2 O 3 , BaCO 3 , and CuO) is 3D-extruded into complex geometries and then reaction-sintered to obtain polycrystalline Y123 + Y211. A seed is then utilized to transform these 3D-printed parts from polycrystal to monocrystal via the melt growth method. The geometric details of 3D-printed parts survive the process without slumping, sagging or collapse, despite the long-term presence of liquid above the peritectic temperature. Origami structures can be created by sheet folding after 3D-printing. This additive approach enables the facile fabrication of superconducting devices with complex shapes and architectures, such as advanced undulator magnets to generate synchrotron radiation and microwave cavities for dark-matter axion search. This work highlights the potential of additive manufacturing for producing monocrystalline cuprate superconductors and opens the door to additive manufacturing of other monocrystalline functional ceramic or semiconductor materials.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Multifunctional Chiral Chemically‐Powered Micropropellers for Cargo Transport and Manipulation

Practical applications of synthetic self-propelled nano and microparticles for microrobotics, targeted drug delivery, and manipulation at the nanoscale are rapidly expanding. However, fabrication limitations often hinder progress, resulting in relatively simple shapes and limited functionality. Here, taking advantage of 3D nanoscale printing, chiral micropropellers powered by the hydrogen peroxide reduction reaction are fabricated. Due to their chirality, the propellers exhibit multifunctional behavior controlled by an applied magnetic field: spinning in place (loitering), directed migration in the prescribed direction, capture, and transport of polymer cargo particles. Design parameters of the propellers are optimized by computation modeling based on mesoscale molecular dynamics. It is predicted by computer simulations, and confirmed experimentally, that clockwise rotating propellers attract each other and counterclockwise repel. These results shed light on how chirality and shape optimization enhance the functionality of synthetic autonomous micromachines.

36 MATERIALS SCIENCE↗