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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
NASA NTRS2005

Condition Assessment and End-of-Life Prediction System for Electric Machines and Their Loads

An end-of-life prediction system developed for electric machines and their loads could be used in integrated vehicle health monitoring at NASA and in other government agencies. This system will provide on-line, real-time condition assessment and end-of-life prediction of electric machines (e.g., motors, generators) and/or their loads of mechanically coupled machinery (e.g., pumps, fans, compressors, turbines, conveyor belts, magnetic levitation trains, and others). In long-duration space flight, the ability to predict the lifetime of machinery could spell the difference between mission success or failure. Therefore, the system described here may be of inestimable value to the U.S. space program. The system will provide continuous monitoring for on-line condition assessment and end-of-life prediction as opposed to the current off-line diagnoses.

Parlos, Alexander G.↗
DOE OSTI2026

Design, Manufacturing, and Validation of an Optimized Electric Machine Enabled by 3D Printing

The collaboration between the National Laboratory of the Rockies (NLR) and LaunchPoint Electric Propulsion Solutions, Inc. (LaunchPoint) focuses on manufacturing and additive design of electric machines enabled by DOE’s program for three-dimensional printing (MADE3D) as applied to advanced drivetrains and their impact on turbine capital cost and lifetime energy production. Initial efforts will focus on the rotor structure and rotor core of the drivetrain including the active materials (electrical steel and magnets) and could later expand to the stator. The verification activities will be conducted with an instrumented electric machine and a small dynamometer.

17 WIND ENERGY↗
NASA NTRS2018

Axial Flux Brushless Permanent Magnet Electrical Machine Rotor

An axial flux brushless permanent magnet electrical machine having a stator and at least one rotor. The rotor includes a Halbach array of magnets with at least four magnets per magnetic cycle. The rotor magnets are contained within pockets in the rotor. The pockets are formed with magnet pocket walls being radial walls, active surface walls, and/or inactive surface walls where the walls retain the magnets within the pockets.

Ricci, Michael Richard↗
NASA NTRS1992

The Bearingless Electrical Machine

Electromagnetic bearings allow the suspension of solids. For rotary applications, the most important physical effect is the force of a magnetic circuit to a high permeable armature, called the MAXWELL force. Contrary to the commonly used MAXWELL bearings, the bearingless electrical machine will take advantage of the reaction force of a conductor carrying a current in a magnetic field. This kind of force, called Lorentz force, generates the torque in direct current, asynchronous and synchronous machines. The magnetic field, which already exists in electrical machines and helps to build up the torque, can also be used for the suspension of the rotor. Besides the normal winding of the stator, a special winding was added, which generates forces for levitation. So a radial bearing, which is integrated directly in the active part of the machine, and the motor use the laminated core simultaneously. The winding was constructed for the levitating forces in a special way so that commercially available standard ac inverters for drives can be used. Besides wholly magnetic suspended machines, there is a wide range of applications for normal drives with ball bearings. Resonances of the rotor, especially critical speeds, can be damped actively.

Bichsel, J.↗
NASA NTRS2019

Progress Toward the Critical Design of the Superconducting Rotor for NASA's 1.4 MW High-Efficiency Electric Machine

NASA Glenn Research Center is developing a 1.4 MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper presents the progress made over the past year toward a critical design of the superconducting rotor, including refined analysis and risk reduction testing on prototype superconducting coils. A 3D finite element model of the rotor is developed to simulate the combined loading imposed by the initial cool down of the rotor from room temperature to cryogenic temperature and the subsequent rotation of the rotor up to the design speed. The model is evaluated to better predict the stress state in the critical components and the reduction in physical gap between the stator and rotor due to the resulting radial deflections. This model includes an enhanced model of the superconducting coil that considers the coil as an assembly of four individual coil layers. An improved coil fabrication process is described in detail. Two sub-scale test coils are fabricated and then tested under repeated thermal cycling between room temperature and liquid nitrogen temperature (77 K). It is demonstrated that the proposed coil fabrication procedure can produce no-insulation, high temperature superconducting coils that can survive several thermal cycles without apparent degradation.

electric machines↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at 6,800 rpm. The design of this cryocooler and testing of its linear motor have been discussed in prior work. This presentation presents the first measurements of the complete HEMM cryocooler. The design and results of a stationary (non-rotating) test of the cryocooler are described.

electrified aircraft propulsion↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗
NASA NTRSDate not supplied

Electrifying Aircraft Propulsion: Thermal Issues of Megawatt Scale Power Dense Electric Machines and Material Solutions

Aircraft are the last major mode of transportation to undergo electrification for many reasons, where the underlying reason is the sensitivity of aircraft performance to mass. This sensitivity demands that efficient, megawatt (MW)-scale high specific power density powertrains be developed to impact regional, single aisle and larger aircraft that account for the majority of fuel burn in commercial aviation. Developing MW-scale high specific power electric powertrains (machines, cables/busbars and power electronics) remains a significant challenge. While advanced power semiconductors have enabled higher voltages, densities, and operational frequencies this also leads to passing high current through smaller volumes when considering electric machines and power electronics. This poses significant thermal challenges. This is particularly true for electric machines that strive to surpass 13 kW/kg, which studies have shown to be desirable for electric aircraft propulsion. The necessity of handling high current densities to achieve MW power levels dictates that greater than 10kW of waste heat will be generated. Moreover, most of the heat is generated in the stator winding which is a mixture of electrical conductor (copper or aluminum), potting material, magnet wire (electrical) insulation and high voltage electrical insulation. Although the electrical conductor is a fantastic thermal conductor, it is also the source of the heat (carrying the electrical current) and is thermally isolated by the other materials. Simply letting the machine run at increased temperatures is an attractive idea, however the reality is that most of the suitable electric insulations and potting material candidates are not likely to satisfactorily operate at higher temperatures with reasonable life expectancies. The likelihood of developing new polymers that can satisfy the necessary functions (mechanical and electrical), operate at higher temperatures with acceptable lifetime in the near term is small. This has led the researchers at the NASA Glenn Research Center to examine electrically insulative materials in high power destiny electric machines, their thermal environment, and what solutions are realistic from a materials point of view. This presentation will touch on both the thermal challenges of electric machines and NASA Glenn’s research into material solutions.

Electric Aircraft Propulsion↗
NASA NTRS2026

A Review of Superconducting Electric Machines with On-Board Cryocoolers

This paper reviews the evolution and emerging direction of superconducting electric machines that employ onboard cryocoolers integrated directly into the rotor, eliminating the need for cryogenic fluid coupling and, in some cases, rotary seals. Traditional low-temperature superconducting (LTS) machines relied on external cryogenic systems and liquid helium transfer couplers, which introduced excessive complexity, poor reliability, and significant parasitic energy losses. The advent of high-temperature superconductors (HTS) has enabled compact, closed-cycle cryocoolers that support self-contained, fluid-free refrigeration architectures suitable for rotating applications. This paper examines the key technological challenges associated with on-board cryocooler integration and reviews three representative efforts by KAIST, NASA, and Hinetics, each illustrating distinct strategies and milestones toward practical implementation. KAIST demonstrated early proof-of-concept for rotating machines with on-board cryocoolers, NASA developed a shaft-integrated Stirling-type pulse tube cryocooler for a 1.4 MW hybrid-electric motor, and Hinetics achieved full-scale validation of a self-contained HTS rotor incorporating a commercial Stirling cryocooler and spoke-suspension torque tube. Collectively, these achievements confirm the technical feasibility of on-board cryogenic refrigeration and highlight steady progress toward compact and efficient superconducting rotating systems across various applications. Embedding cryocoolers directly within the rotor enables practical, efficient, and commercially viable superconducting propulsion technologies.

Cryogenics↗
DOE OSTI2026

A Unified Scaling Framework for Comparative Analysis of Major Electrical Machine Topologies

This paper presents a unified framework for comparing major electrical machine topologies under identical output and thermal constraints, with emphasis on supply-chain-aware selection among rare-earth-intensive, reduced-rare-earth, and rare-earth-free solutions. Using power factor and air-gap flux density as the principal descriptors, the framework links topology choice to relative size, copper demand, magnet dependence, cost sensitivity, and inertia. To support robust early-stage screening, the deterministic scaling model is combined with uncertainty representation, Monte Carlo scenario propagation, and hesitationaware ranking. The results show that rare-earth-rich machines remain compact and dense, whereas reduced-rare-earth and rare-earth-free alternatives become more attractive under specific material-risk and cost scenarios.

Kumar, Praveen [ORNL] (ORCID:0000000291877857)↗
NASA NTRS2019

Progress Toward the Critical Design of the Superconducting Rotor for NASA's 1.4 MW High Efficiency Electric Machine

NASA Glenn Research Center is developing a 1.4 MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper presents the progress made over the past year toward a critical design of the superconducting rotor, including refined analysis and risk reduction testing on prototype superconducting coils. A 3D finite element model of the rotor is developed to simulate the combined loading imposed by the initial cool down of the rotor from room temperature to cryogenic temperature and the subsequent rotation of the rotor up to the design speed. The model is evaluated to better predict the stress state in the critical components and the reduction in physical gap between the stator and rotor due to the resulting radial deflections. This model includes an enhanced model of the superconducting coil that considers the coil as an assembly of four individual coil layers. An improved coil fabrication process is described in detail. Two sub-scale test coils are fabricated and then tested under repeated thermal cycling between room temperature and liquid nitrogen temperature (77 K). It is demonstrated that the proposed coil fabrication procedure can produce no-insulation, high temperature superconducting coils that can survive several thermal cycles without apparent degradation.

Scheidler, Justin↗
NASA NTRS1980

Determination of efficiencies, loss mechanisms, and performance degradation factors in chopper controlled dc vehical motors. Section 2: The time dependent finite element modeling of the electromagnetic field in electrical machines: Methods and applications

The time dependent solution of the magnetic field is introduced as a method for accounting for the variation, in time, of the machine parameters in predicting and analyzing the performance of the electrical machines. The method of time dependent finite element was used in combination with an also time dependent construction of a grid for the air gap region. The Maxwell stress tensor was used to calculate the airgap torque from the magnetic vector potential distribution. Incremental inductances were defined and calculated as functions of time, depending on eddy currents and saturation. The currents in all the machine circuits were calculated in the time domain based on these inductances, which were continuously updated. The method was applied to a chopper controlled DC series motor used for electric vehicle drive, and to a salient pole sychronous motor with damper bars. Simulation results were compared to experimentally obtained ones.

Hamilton, H. B.↗
NASA NTRS2023

Static Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for A 1.4 MW Electric Machine in a Thermal Vacuum Chamber

NASA’s high efficiency megawatt motor (HEMM) is a partially superconducting, 1.4 MW electric machine designed for electrified aircraft propulsion. HEMM’s high performance is enabled by a field winding composed of 2nd generation high temperature superconducting (HTS) coils that are designed to operate at temperatures below 62 K. The superconducting rotor is conductively cooled to cryogenic temperatures using a rotating cryocooler embedded inside the machine’s shaft. This paper presents a static test of the full-scale superconducting rotor in a thermal vacuum chamber. The experimental setup is described in detail. Thermal and electromagnetic 3D finite element analyses of the experimental setup are shown along with a comparison of the model results to model results for HEMM. The thermal response during cool down from room temperature is discussed. Electrical measurements are presented for operation at different dc current excitations up to the rated current of the rotor (57.2 A) and temperature limit of the HEMM design (62 K). The results suggest that minor damage to one superconducting coil occurred at 50 A and 61.2 K, causing increased resistance in the system, but that the system could still be stably operated at 57.2 A and 62 K when conductively cooled by a cryocooler.

electrified aircraft propulsion↗
DOE OSTI2025

Electromagnetic Modeling of Lattice Structures in Additively Manufactured Electric Machines

Recent advancements in metal additive manufacturing (AM) show great potential to revolutionize the design and manufacturing of electromagnetic components used in the field of electrical engineering. Lattice structures directly printed by AM processes typically offer better structural performance with reduced weight, such as high stiffness, surface area, elongation, energy absorption, and porosity, than the solid counterpart. This paper aims to study the electromagnetic modeling of lattice structures used in additively manufactured magnetic cores or windings for electric machines. Three dimensional (3D) electromagnetic finite element (FE) analysis with high performance computing (HPC) shows the highest fidelity in predicting the electromagnetic performance of designs with lattice structures by preserving complex geometry details. FE-based homogenization methods have also been explored to potentially speed up concept design. A case study based on an additively manufactured axial-flux permanent magnet machine with a Hilbert pattern stator validates the discussed electromagnetic modeling approaches.

Chung, Shi-Uk [ANSYS, Inc.]↗
NASA NTRS1976

Sample preparation of metal alloys by electric discharge machining

Electric discharge machining was investigated as a noncontaminating method of comminuting alloys for subsequent chemical analysis. Particulate dispersions in water were produced from bulk alloys at a rate of about 5 mg/min by using a commercially available machining instrument. The utility of this approach was demonstrated by results obtained when acidified dispersions were substituted for true acid solutions in an established spectrochemical method. The analysis results were not significantly different for the two sample forms. Particle size measurements and preliminary results from other spectrochemical methods which require direct aspiration of liquid into flame or plasma sources are reported.

Chapman, G. B., II↗
NASA NTRS1983

Six-Axis Electrical-Discharge Machine

Electrical discharge machine (EDM) of unusual versitility made by conversion of radial drill. Drilling head is replaced by ram that holds and positions electrode. Tank and recirculation system for coolant are added. EDM has six independent motions and drastically reduced cost of manufacturing. New applications are constantly being found.

Werner, A. R.↗
DOE OSTI2024

Improving Efficiency of Off-Road Vehicles by Novel Integration of Electric Machines and Advanced Combustion Engines

Modern off-road equipment will increasingly rely on electrified implements that will deliver precision control with a smaller footprint than hydraulics. The primary energy converter, however, will be an onboard reciprocating internal combustion engine because of the power density of hydrocarbon fuels in comparison to electrical energy storage and the remote locations where much of this equipment is deployed. Adding energy storage and electric machines creates opportunities to improve efficiency while reducing emissions. This program investigated approaches to take advantage of the extra flexibility that an enhanced electrical system to enable high-efficiency, low-emissions combustion technologies. The current program evaluated hybridization of both the torque application and air-handling systems to maximize efficiency while minimizing cost. This program designed, analyzed and tested a hybrid off-road vehicle consisting of a series electric powertrain with energy storage, an electrified air system, and a 33% downsized diesel engine. Detailed comparisons were made between the base powertrain and the developed powertrain using powertrain simulations, engine testing, and vehicle testing. The key results of the study are: • The resulting vehicle reduces fuel consumption by 5% to 15% at equal productivity. The primary improvements were due to recovery of regenerative braking losses for cycles where large transients are encountered. • The electrified air system was an enabler to allow engine downsizing. This was most important for duty-cycles where the engine primarily operated at moderate loads and had few low speed high torque conditions. • Engine level improvements showed re-optimization of the powertrain is possible when electrified air handing is available. Increased exhaust gas recirculation and advanced injection timing allowed up to a 15% reduction in brake specific fuel consumption at equal NOx and transient response. Compared to the larger engine, the downsized engine achieves up to an 18% reduction in brake specific fuel consumption over the non-road transient cycle. • The life cycle analysis and total cost of ownership study showed that the hybrid powertrain has the potential to reduce 5-year CO2 and total cost of ownership by ~6% over the baseline vehicle. The results also indicated that a pure battery electric vehicle is not feasible in this application and is likely to increase the CO2 emissions due to the CO2 from battery production. A hybrid powertrain with low carbon fuels shows the potential to substantially reduce CO2 and total cost of ownership.

02 PETROLEUM↗
NASA NTRSDate not supplied

Thermally Conductive Insulation for High Power Density Electric Machines

In the mid 2000’s NASA challenged the aeronautics industry to identify the routes for achieving ambitious improvements in fuel burn, emission, and noise reductions. These so-called “N+3” studies were exploring broad changes three commercial aircraft generations, or nominally 30 years, in the future. Many intriguing propulsion-airframe integrated solutions were proposed and pursued, which incorporated technologies such as high-aspect-ratio wings, boundary-layer ingestion, and hybrid electric powertrains. This talk summarizes the approaches and achievements from the Hybrid Gas-Electric Propulsion Concept Technical Challenge that concluded in 2019. The balanced portfolio of concepts studies anchored with practical technology development demonstrated that electrified aircraft propulsion is an aircraft revolution whose time has come. Advanced materials will play a key role with enabling the increase in operating efficiencies and lifetime of these high power-dense electric machines. Progress made in materials development as part of NASA’s Advanced Air Transport Technology project will also be discussed.

electrical insulation↗