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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 OSTI2021

Flux Switching Permanent Magnet Motor with Metal Amorphous Nanocomposite Soft Magnetic Material and Rare Earth Free Permanent Magnets

The power losses in high power-density motors due to high rotational speed and/or high pole counts may be reduced adopting metal amorphous nanocomposites (MANCs) featuring low power loss and a relatively high flux density (~1.3 T). We recently proposed a flux switching permanent magnet (FSPM) motor with a rating of 2.5 kW at 1400 Hz electrical speed by incorporating low loss (< 3 W/kg at 1 kHz) FeNi-based MANC material with projected iron loss of about 5 W. The motor design allows use of rare earth-free permanent magnets. For incorporation of MANC materials, an axial flux motor where the rotor and stator core are made from a wound ribbon core has been developed. We have performed a 3-d FEA to optimize the design and built and tested a prototype demonstrating that the low loss MANC material can be used for motor applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Status of permanent magnet radiation resiliency studies at CEBAF

An ongoing investigation for the future of Jefferson Lab’s Continuous Electron Beam Accelerator Facility (CEBAF) lies in upgrading its maximum nominal energy using Fixed-Field Alternating-gradient (FFA) technology for its recirculating arcs, using permanent magnets for the FFA arcs. A common concern among the community is the degradation of these permanent magnets during operation due to the radiation environment in which they will be present. This work, funded by a Laboratory Directed R&D grant, aims to measure the permanent magnet degradation in the CEBAF tunnel enclosure, and extrapolate to the energies expected from the upgrade. We present the latest results of this study, as well as plans moving forward.

Accelerator Physics↗
DOE OSTI2021

Semihard Iron-Based Permanent-Magnet Materials

Permanent magnets generally require a favorable, but difficult-to-achieve combination of high magnetization, Curie point, and magnetic anisotropy. Thus there have been few, if any, viable permanent magnets developed since the 1982 discovery of Nd 2 Fe 14 B. In this work we point out, both by direct first-principles calculations on the iron carbides and silicides Fe 5 C 2 , Fe 5 SiC, and Fe 7 C 3 as well as a discussion of recent experimental findings, that there are numerous rare-earth-free iron-rich potential permanent-magnet materials with sufficient intrinsic magnetic properties to reasonably achieve room-temperature energy products of 20–25 MG Oe. This is substantially better than the performance of the best available rare-earth-free magnets based on ferrite, as well as shape-anisotropy-employing alnico. These magnets could plausibly fill, at low cost, the present performance “gap” between the best rare-earth-free magnets and rare-earth magnets such as Nd 2 Fe 14 B and Sm-Co.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Additive manufacturing of permanent magnets

Here, permanent magnets enable energy conversion. Motors and generators are used to convert both electrical to mechanical energy and mechanical to electrical energy, respectively. They are precharged (magnetized) prior to being used in an application and must remain magnetized during operation. In addition, they should generate sufficient magnetic flux for a given application. Nevertheless permanent magnets can be demagnetized (discharged of their magnetization) by other magnetic materials in their service vicinity, temperature changes (thermal demagnetization), microstructural degradations and the magnet’s internal demagnetizing field. Therefore a permanent magnet can be qualified based on the properties that measure its ability to withstand demagnetization and to supply sufficient magnetic flux required for a given application. Some of those properties are further discussed below. Additive manufacturing followed by exchange spring magnets will be discussed afterwards.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Permanent Magnet Synchronous Condenser with Solid State Excitation

A synchronous condenser consists of a free-spinning wound-field synchronous generator and a field excitation controller. In this paper, we propose a synchronous generator that employs a permanent magnet synchronous generator (PMSG) instead of a wound-field machine. PMSGs have the advantages of higher efficiency and reliability. In the proposed configuration, the reactive power control is achieved by a voltage source converter connected in series with the PMSG and the grid. The converter varies the phase voltage of the PMSG so as to create the same effect of over or under excitation in a wound-field machine. The converter output voltage level controls the amount and the direction of the produced reactive power and the voltage's phase is kept in-phase with the grid voltage except a slight phase can be introduced so that some power can be drawn from the grid for maintaining the DC bus voltage level of the converter. Since the output voltage of the converter is only a fraction of the line voltage, its VA rating is only a fraction of the rating of the PMSG. The proposed scheme is shown to be effective by computer simulation.

17 WIND ENERGY↗
DOE OSTI2015

Cluster expansion modeling and Monte Carlo simulation of alnico 5–7 permanent magnets

The concerns about the supply and resource of rare earth (RE) metals have generated a lot of interests in searching for high performance RE-free permanent magnets. Alnico alloys are traditional non-RE permanent magnets and have received much attention recently due their good performance at high temperature. In this paper, we develop an accurate and efficient cluster expansion energy model for alnico 5–7. Monte Carlo simulations using the cluster expansion method are performed to investigate the structure of alnico 5–7 at atomistic and nano scales. The alnico 5–7 master alloy is found to decompose into FeCo-rich and NiAl-rich phases at low temperature. The boundary between these two phases is quite sharp (∼2 nm) for a wide range of temperature. The compositions of the main constituents in these two phases become higher when the temperature gets lower. Both FeCo-rich and NiAl-rich phases are in B2 ordering with Fe and Al on α-site and Ni and Co on β-site. The degree of order of the NiAl-rich phase is much higher than that of the FeCo-rich phase. A small magnetic moment is also observed in NiAl-rich phase but the moment reduces as the temperature is lowered, implying that the magnetic properties of alnico 5–7 could be improved by lowering annealing temperature to diminish the magnetism in NiAl-rich phase. The results from our Monte Carlo simulations are consistent with available experimental results.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Universal Electronic‐Structure Relationship Governing Intrinsic Magnetic Properties in Permanent Magnets

An electronic-structure-centered perspective is presented on permanent-magnet (PM) design, highlighting two key levers, that is, saturation magnetization (M s ), governed by 3d-band filling and exchange physics, and magnetocrystalline anisotropy energy (MAE), arising from spin-orbit coupling (SOC) on anisotropic orbital populations. Reviewing current practices, including DFT-based MAE/J ij extraction, atomistic-spin and micromagnetic modeling, and high-throughput machine learning (ML) pipelines, three bottlenecks limiting predictive discovery is identified that is i) electronic-structure accuracy for small MAE (sensitive to functional choice, Hubbard U, and many-body effects), ii) finite-temperature and kinetic realism (phonon/magnon renormalization, ordering kinetics), and iii) descriptor and multiscale decoupling (lack of SOC-weighted and orbital-resolved fingerprints). Deep dives into the electronic-structure of Nd─Fe─B and Fe─N show how these fingerprints govern magnetic performance, motivating DFT- and quantum-mechanics-based descriptors for discovery. Unbiased, structure-driven exploration, coupled with high-throughput simulations, ML, generative AI, and reasoning models, accelerates candidate identification and propagates insights across scales. Addressing supply-chain risks, on future needs of designing “critical-element-free” magnets with tailored microstructure and high energy products is emphasized. By integrating electronic fingerprints, AI reasoning, and multiscale modeling, a practical roadmap is provided for rare-earth-lean or rare-earth free, high-performance, sustainable PMs.

Singh, Prashant [Ames Laboratory, and Iowa State U↗
DOE OSTI2016

Improved inertial control for permanent magnet synchronous generator wind turbine generators

With increasing integrations of large‐scale systems based on permanent magnet synchronous generator wind turbine generators (PMSG‐WTGs), the overall inertial response of a power system will tend to deteriorate as a result of the decoupling of rotor speed and grid frequency through the power converter as well as the scheduled retirement of conventional synchronous generators. Thus, PMSG‐WTGs can provide value to an electric grid by contributing to the system's inertial response through the inherent kinetic energy stored in their rotating masses and fast power converter control. In this study, an improved inertial control method based on the maximum power point tracking operation curve is introduced to enhance the overall frequency support capability of PMSG‐WTGs in the case of large supply–demand imbalances. Moreover, this method is implemented in the CART2‐PMSG integrated model in MATLAB/Simulink to investigate its impact on the wind turbine's structural loads during the inertial response process. Simulation results indicate that the proposed method can effectively reduce the frequency nadir, arrest the rate of change of frequency, and alleviate the secondary frequency dip while imposing no negative impact on the major mechanical components of the wind turbine.

Wu, Ziping↗
DOE OSTI2022

Electron Accelerator Lattice Design for LHeC with Permanent Magnets

We present a new ’green energy’ approach to the Energy Recovery Linac (ERL) the future Electron Ion Collider at LHeC using single beam line made of very strong focusing combined function permanent magnets and the Fixed Field Alternating Linear Gradient (FFA-LG) principle. We are basing our design on recent very successful commissioning results of the Cornell University and Brookhaven National Laboratory ERL Test Accelerator-CBETA.

Trbojevic, D.↗
DOE OSTI2022

PM4Stell: A prototype permanent magnet stellarator structure

Permanent magnets provide a possible solution to simplify complicated stellarator coils. Here, a prototype permanent magnet stellarator structure, PM4Stell, has been funded to demonstrate the technical feasibility of using permanent magnets to create the shaping field of a stellarator. Permanent magnets in uniform cubes with three polarization directions will be carefully placed to generate the required magnetic field for a National Compact Stellarator eXperiment-like equilibrium together with planar toroidal field coils. Discrete magnets will be glued together and inserted into a “post-office-box-like” supporting structure. Electromagnetic and structural analyses have been done to validate the design. Error field correction magnets will be used to shim possible error fields. The design efforts of the prototype permanent magnet stellarator structure are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Directly obtained τ-phase MnAl, a high performance magnetic material for permanent magnets

The metastable tetragonal τ-phase has been directly obtained from casting Mn{sub 0.54}Al{sub 0.46} and (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} using the drop synthesis method. The as-casted samples were ball milled to decrease the particle size and relaxed at 500 °C for 1 h. The phase composition, crystallographic parameters, magnetic properties and microstructure were systematically studied. The results reveal that the τ-phase could be directly obtained from drop synthesis. The highest M{sub s} of 117 emu/g was achieved in the (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} where the τ-phase was stabilized by doping with carbon. Carbon doping increased the c/a ratio of the τ-phase as it occupies specific interstitial positions (½, ½, 0) in the structure. Furthermore, ball milling increases the coercivity (H{sub c}) at the expense of a decrease in magnetic saturation (M{sub s}). The increase in coercivity is explained by a decrease of grain size in conjunction with domain wall pinning due to defects introduced during the ball milling process. - Graphical abstract: The tetragonal τ-phase has been directly obtained from casting Mn{sub 0.54}Al{sub 0.46} and (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} using the drop synthesis method. The phase composition, crystallographic parameters, magnetic properties and microstructure were systematically studied. The highest M{sub s} of 117 emu/g was achieved for (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2} ball milling increases the coercivity (H{sub c}) at the expense of a decrease in magnetic saturation (M{sub s}). - Highlights: • The ferromagnetic τ-phase has been directly obtained from casting. • The highest M{sub s} of 117 emu/g was achieved for (Mn{sub 0.55}Al{sub 0.45}){sub 100}C{sub 2}. • Ball milling increases the coercivity but decreases the magnetic saturation.

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

An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles

This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

A solid-state extrusion pathway extensible to upcycling aluminum scrap and end-of-life permanent magnets into ductile Al-6061/SmCo 5 structural magnetic composites

Permanent magnets offer strong potential for multifunctional structural components, but their inherent brittleness limits direct integration. Here, SolidStir® Extrusion (SSE) is used to embed SmCo5 powder into AA6061 in the solid state, and the resulting microstructure, interfacial chemistry, mechanical properties, and magnetic response are systematically characterized. SSE fragments the initial SmCo 5 powder into predominantly fine particles dispersed within an ultrafine Al matrix, with a volume fraction of ∼ 4–6 % in this proof-of-concept study. Interfacial reactions form a continuous Al–Co reaction layer, with local atomic-resolution indexing consistent with Al 13 Co 4 , together with Sm–Si-rich reaction products, while the matrix contains Sm–Co–Si-rich precipitates and Mg 2 Si, producing features from nanometers to micrometers. Compared with an Al extrudate, this architecture increases yield strength by ∼ 42 % and tensile strength by ∼ 31 %, while preserving uniform elongation, and it sustains work hardening in compression from 150 to 400 °C. The composite retained hard-magnetic behavior, with axial magnetization of 12.7 A·m 2 kg −1 at 6 T and intrinsic coercivity of 9.6 kOe. These findings demonstrate that SSE can produce Al-based load-bearing magnetic composites while preserving useful SmCo5 functionality.

36 MATERIALS SCIENCE↗