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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 OSTI2025

Interpretable machine learning-guided design of Fe-based soft magnetic alloys

Here, we present a machine learning (ML) guided approach to predict saturation magnetization (𝑀 S ) and coercivity (𝐻 C ) in Fe-rich soft magnetic alloys, particularly Fe-Si-B systems. ML models trained on experimental data reveal that increasing Si and B content reduces 𝑀 S from 1.81 T (DFT ≈ 2.04 T) to ≈1.54 T (DFT ≈ 1.56T) in Fe-Si-B, which is attributed to decreased magnetic density and structural modifications. Experimental validation of ML predicted magnetic saturation on Fe-1Si-1B (2.09 T), Fe-5Si-5B (2.01 T), and Fe-10Si-10B (1.54 T) alloy compositions further supports our findings. These trends are consistent with density functional theory predictions, which link increased electronic disorder and band broadening to lower 𝑀 S values. Experimental validation on selected alloys confirms the predictive accuracy of the ML model, with good agreement across compositions. Beyond predictive accuracy, detailed uncertainty quantification and model interpretability including through feature importance and partial dependence analysis reveal that 𝑀 S is governed by a nonlinear interplay between Fe content and early transition metal ratios, while 𝐻 C is more sensitive to processing conditions such as ribbon thickness and thermal treatment windows. The ML framework was further applied to Fe-Si-B/Cr/Cu/Zr/Nb alloys in a pseudoquaternary compositional space, which shows comparable magnetic properties to NANOMET (Fe 84.8 ⁢Si 0.5 ⁢B 9.4 ⁢Cu 0.8⁢ P 3.5 ⁢C 1 ), FINEMET (Fe 73.5 ⁢Si 13.5 ⁢B 9 Cu 1 ⁢Nb 3 ), NANOPERM (Fe 88 ⁢Zr 7⁢ B 4 ⁢Cu 1 ), and HITPERM (Fe 44 ⁢Co 44 ⁢Zr 7⁢ B 4 ⁢Cu 1 . Our findings demonstrate the potential of the ML framework for accelerated search of high-performance soft magnetic materials.

density functional theory↗
DOE OSTI2025

A Mössbauer Spectroscopy Investigation of Nickel‐Zinc Ferrites Synthesized by a Self‐Combustion Method for Soft Magnetic Core Applications

Soft ferrites are materials of interest for magnetic cores, as used for wireless charging transformers. Their low permeabilities, high resistivity, and magnetic polarization make them interesting for high-power electric vehicle charging and drive systems. The nickel-zinc-doped ferrites are of particular interest; however, the compositional space is quite large with respect to dopant concentrations, stoichiometric ratios and synthesis technique. Nickel-zinc spinel ferrites with varying nickel-zinc ratios prepared by a self-combustion reaction followed by heat treatment exhibit good crystallinity, and their low-temperature Mössbauer spectra show local magnetism and site occupation in agreement with materials prepared by solid-state reaction. Thus, the combustion synthesis method offers a facile tunability of compositions, which, combined with the possibility of rapid characterization of atomic-scale magnetism by Mössbauer spectroscopy, enables advances in the compositional and processing space at a fast pace. Low-temperature Mössbauer spectroscopy data for samples with increasing nickel content reveals a systematic increase in average hyperfine field (2.8 T/Ni) and decrease in average isomer shift (−0.036 mm/s/Ni) that can determine the nickel/zinc content, even in the absence of applied magnetic field data. Furthermore, a gradual evolution of color is also observed with increasing nickel content, albeit trends in color depend on sintering conditions.

Mössbauer spectroscopy↗
DOE OSTI2021

Role of scan strategies and heat treatment on grain structure evolution in Fe-Si soft magnetic alloys made by laser-powder bed fusion

A major goal in printing soft magnetic Fe-Si steels using additive manufacturing is to take advantage of the potential for complex geometric designs and site-specific grain control. One major step in the processing of these alloys is understanding how processing parameters might impact how the as-built microstructure responds to annealing (i.e. the annealing response). The impact of scan strategy on the annealing response for thin wall geometries is specifically explored. Two scan strategies were explored for a thin wall geometry that produced a strongly columnar grain structure and equiaxed grain structure. Additionally, samples from both scan strategies annealed at 1200 °C showed a marked difference in annealing response with the more equiaxed sample seeing full recrystallization and grain growth, while the more columnar grain structure saw little change in microstructure. After analysis through characterization techniques and thermal-mechanical simulations Differences in internal energy within the grains were ruled out because calculated GND density values were similar for both samples. The formation of secondary particles was ruled out as a contributing factor due to the type of oxide formations and their size. It was concluded that the contributing factor to the difference in the annealing response were a difference in the resulting grain size and the density of high angle grain boundaries. These two differences were largely attributed to differences in the thermal gradient conditions due to grains preferentially growing in the direction of the steepest thermal gradient.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bottom-Up Soft Magnetic Composites (FY 2022 Annual Progress Report)

The project objective is to develop high-magnetization, low-loss iron nitride based soft magnetic composites for electrical machines. These new SMCs will enable low eddy current losses and therefore highly efficient motor operation at rotational speeds up to 20,000 rpm. Additionally, iron nitride and epoxy composites will be capable of operating at temperatures of 150 °C or greater over a lifetime of 300,000 miles or 15 years.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bottom-Up Soft Magnetic Composites

The project objective is to develop high-magnetization, low-loss iron nitride based soft magnetic composites for electrical machines. These new SMCs will enable low eddy current losses and therefore highly efficient motor operation at rotational speeds up to 20,000 rpm. Additionally, iron nitride and epoxy composites will be capable of operating at temperatures of 150 °C or greater over a lifetime of 300,000 miles or 15 years.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗
DOE OSTI2022

Nanostructure refinement and phase formation of flash annealed FeNi-based soft magnetic alloys

In this work, the resulting nanocomposite microstructures of FeNi nanocrystallites under different heating and cooling rates (5 °C/min vs 400-500 °C/s) is investigated. Conventional furnace annealing under low heating rates and slow cooling resulted in both BCC α-FeNi and FCC γ-FeNi nanocrystallites with an average grain size on the order of 25-27 nm whereas high heating rates achieved via flash annealing techniques have enabled a dramatically refined microstructure consisting of 5-7 nm grains with FCC γ-FeNi phase and found to be the dominant phase following primary crystallization. Grain size refinement and phase identity optimization yielded low values of coercivities-17 A/m and high permeability similar to 11 x 10 3 measured at 400 Hz/1 kA/m in flash annealed samples at 450 °C for 5 s. The magnetic behavior and the underlying mechanism of optimal soft magnetic properties are discussed in terms of the critical role of the grain size in domain wall pinning and coercivity.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ENVIRONMENTAL DEGRADATION OF HARD AND SOFT MAGNETIC MATERIALS IN GASEOUS AND SUPERCRITICAL CO2 ENVIRONMENTS

It may be beneficial to use hermetic designs for supercritical CO2 (sCO2) cycles machinery as they would eliminate CO2 leakage through shaft end seals. This would reduce CO2 emissions and operating costs for makeup of lost process fluid. Those designs may replace traditional oil-lubricated bearings with actively controlled magnetic bearings operating at high temperatures in the process fluid environment (to reduce the need for active cooling). This paper investigates the material degradation of various types of magnets in CO2. Included are several permanent and soft magnetic materials (Alnico 9C, Alnico 5-7C, and 18-T550 grade SmCo, and Hiperco 50) with or without coatings (nickel plating or C5 coating). The materials were exposed to: (1) flowing gaseous CO2 at 1,022 °F (550 °C) and atmospheric pressure in a furnace and (2) sCO2 at 842 °F (450 °C) and 1,500 psi (103 bar) in an autoclave. The preliminary mass change measured after total exposures of 1,000 hours and 2,000 hours are included.

supercritical CO2, magnetic material↗
DOE OSTI2024

Wet chemistry-synthesized Fe/mixed ferrite soft magnetic composites for high-frequency power conversion

State-of-the-art soft magnetic (SM) alloy systems such as electrical steels and permalloys exhibit large eddy current losses at high-frequency (kHz range and above), limiting their application in fast switching devices. Eddy current losses can be reduced for metallic alloys through a decrease in characteristic length scale or embedding them in an insulation layer. This work proposes the development of fine-scale core materials consisting of metallic SM nano/microparticles with magnetic, inorganic insulation layers, and their synthesis using a wet chemistry-based, scalable method for high frequency and high-power applications. More specifically, a magnetic ferrite coating (Ni 0.5-x Mn x Zn 0.5 Fe 2 O 4 , x = 0.0–0.5) was applied via deposition of ferrite powder produced using a “wet chemistry-based” co-precipitation method; the ferrite was distributed through the Fe micropowder via either ball milling or ultrasonic mixing. Powder cores were prepared by compaction of the synthesized composites. Relative magnetic permeability and core loss were measured at excitation frequencies to 200 kHz. A core loss of 127 kW/m 3 was measured at excitation frequency of 100 kHz and magnetization of 0.02 T. This value improves on the 199.3 kW/m 3 reported in literature at identical excitation conditions for a compact formed from a composite comprising Fe microparticles coated with low-permeability Ni 0.5 Zn 0.5 Fe 2 O 4 . Ultrasonic mixing resulted in slightly lower core loss than ball milling, possibly because ball milling causes loss-increasing deformation of the Fe micropowder. XRD and SEM were used to observe composite composition and core cross-section microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Soft magnetic alloy embodiments for additive manufacturing and geometric structures formed therefrom

Disclosed herein are embodiments of soft magnetic alloy embodiments for use in additive manufacturing and structures fabricated from such alloys. In some embodiments, the fabricated structures comprise a continuous thin wall (or plurality thereof) having a geometry that promotes reduced eddy current losses and other performance enhancements. In some embodiments, the fabricated structures are used to make components, such as transformer cores and/or electric motors.

Plotkowski, Alexander↗
DOE OSTI2025

Influence of Solidification Velocity on Partitioning and Precipitate Evolution in a Multicomponent, Soft Magnetic Alloy Processed by Laser Melting

Multicomponent alloys have recently been shown to overcome the structural-functional barrier associated with soft magnetic materials. Here, single laser tracks have been used to investigate the effects of solidification velocity on the Al 7 Fe 32.6 Co 27.7 Ni 27.7 Ta 5 (at pct) alloy. Ta-rich cell wall partitioning was shown to affect the final distribution and size of the precipitating L1 2 phase, after aging. These findings demonstrate that solidification rate control offers the potential to tailor localized performance in alloys with size-dependent precipitation properties.

Brookins, Jeffrey M. [Oak Ridge National Laborator↗
DOE OSTI2023

Design, Modeling, and Testing of a Novel Inductor for Electric Vehicles: Iron Nitride Soft Magnetic Composites

New technology for electric vehicles (EVs) must meet the requirements of higher energy usage, lower costs, and more sustainable source materials. One promising material for EV power system components is iron nitride (IN) soft magnetic composites (SMCs) because of their competitive magnetic properties and high abundance of the source materials. As part of an ongoing program at Sandia National Laboratories, this project focused on using computer modeling to optimize the prototyping process for an iron nitride SMC toroidal inductor to reach a target inductance of 600 μH. Four inductors with different combinations of wiring (26 AWG and 20 AWG) and vol% loading of iron nitride (65 vol% and 50 vol%) were fabricated at Cal Poly and characterized using an LCR meter. These inductors were also modeled using COMSOL Multiphysics™ with the Magnetic Fields module. The inductance data from the experiment and the model show that the 65 vol% IN prototypes and models agree with about 8% difference, while the 50 vol% IN samples show about a 9% difference between the prototype and the model. These results suggest that the model can predict inductance with both accuracy and precision with low confidence for the given sample size of four. An additional parameter of AC resistance is studied but the AC resistance results from the inductors and from the model generally do not agree closely, suggesting that the current model used in the project does not fully capture the mechanisms behind AC resistance of the inductor. With the focus of the project on inductance, the percent difference results of less than 9% across the four inductors that were tested increases confidence in the model’s predictive capabilities for inductance only. Using the inductance results from both the model and experiment, the final suggested inductor design is a 65 vol% core with 150 windings of 20 AWG wire that is 8 cm across and 1.5 cm tall to reach the inductance goal of 600 μH based on analysis using the optimized COMSOLTM model.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Synthesis and behavior of bulk iron nitride soft magnets via high-pressure spark plasma sintering

Abstract In this study, dense bulk iron nitrides (Fe x N) were synthesized for the first time ever using spark plasma sintering (SPS) of Fe x N powders. The Fe 4 N phase of iron nitride in particular has significant potential to serve as a new soft magnetic material in both transformer and inductor cores and electrical machines. The density of SPSed Fe x N increased with SPS temperature and pressure. The microstructure of the consolidated bulk Fe x N was characterized with X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and superconducting quantum interference device (SQUID) magnetometry. XRD revealed a primary phase of Fe 4 N with secondary phases of Fe 3 N and metallic iron. Finite element analysis (FEA) was also applied to investigate and explain localized heating and temperature distribution during SPS. The effects of processing on interface bonding formation and phase evolution were investigated and discussed in detail to provide insight into fundamental phenomena and microstructural evolution in SPSed Fe x N. Graphic abstract

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling and Measuring the Stress Distribution in Soft Magnetic Cores due to Epoxy Impregnation and Curing

Understanding the effects of viscoelastic relaxation of stresses is critical in electric motor and inductor applications, where the magnetic material is fully or partially comprised of an amorphous phase and impregnated in an epoxy. Magnetic Amorphous Nanocomposites (MANCs) are a class of recently developed high-frequency magnetic materials that exhibit low magnetic hysteresis, high saturation flux density and very low AC magnetic losses. MANCs are formed as long, thin ribbons, a shape factor that minimizes eddy current-induced self-heating. This feature, in addition to their 1 GPa strength, and makes them attractive candidates for high-speed, high-power density, electric motors. MANCs are used in the form of tape-wound cores (TWCs). During the manufacturing process, the cores are impregnated with liquid epoxy between each layer of ribbon. Validated knowledge of the stresses imposed by the manufacturing process and during operation is necessary to understand motor performance limitations with respect to strength. Magnetostriction, the strain imposed by reversal of the magnetic field, also affects performance. When the epoxy cures, it contracts volumetrically by 8%, imposing radial and circumferential stresses that vary along the radial direction. To date, these stresses have received little attention in the literature. Here, we model the stress distribution throughout a TWC due to epoxy curing. Strain gauge measurements reported here indicate substantially lower tangential strain than model values, which is beneficial and which we attribute to viscoelastic relaxation of the epoxy layers. We will incorporate a constitutive model of this viscoelastic relaxation, and conduct more detailed strain measurements to understand how this takes

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

The Ductility of 49Fe-49Co-2V Soft Magnetic Alloy Bar: Surface Effects and Test Methods

The tensile ductility of 49Fe-49Co-2V (Hiperco® 50A) bar was investigated in both as-received and heat-treated conditions. The as-received/machined specimens exhibit very low ductility compared to samples where heat treatment was the final step prior to testing. Microstructural characterization showed that internal residual strain from bar processing and, most importantly, surface machining damage, cause lower elongation in the as-received material. Because fracture of this intermetallic alloy initiates at the surface, it is particularly susceptible to surface machining damage, i.e., the near-surface region has already exhausted most of its ability to accumulate tensile strain. During heat treatment, the internal residual strain and near-surface machining damage are eliminated and ductility is improved, despite a higher degree of crystallographic ordering in the heat-treated condition (which typically lowers ductility). Furthermore, if machining is again performed after heat treatment, the material again exhibits brittle behavior, even with only light touch-up machining passes. Here, in this work, methods of tensile strain measurement were investigated, namely conventional knife-edge extensometry and noncontact digital image correlation (DIC) on heat-treated material. For clip-on knife-edge extensometry, the range of failure strain was 2.5-5.5% for heat-treated Hiperco. For noncontact methods, ductility up to 7% was observed. The results highlight the tendency for the alloy to fail at surface imperfections, even those produced by application of the extensometer itself. Noncontact laser extensometry is recommended for determining the intrinsic ductility of the alloy. A method of laser surface modification was developed which increased ductility by ~ 100% compared to unmodified samples. The high cooling rates achieved during laser surface processing can bypass the ordering reaction and produce a ductile disordered structure at the surface that exhibits ductile fracture characteristics.

EBSD↗