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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Emerging magnetic materials for electric vehicle drive motors

Abstract Increasing demand for electric vehicles (EVs) is increasing demand for the permanent magnets that drive their motors, as approximately 80% of modern EV drivetrains rely on high-performance permanent magnets to convert electricity into torque. In turn, these high-performance permanent magnets rely on rare earth elements for their magnetic properties. These elements are “critical” (i.e., at risk of limiting the growth of renewable energy technologies such as EVs), which motivates an exploration for alternative materials. In this article, we overview the relevant fundamentals of permanent magnets, describe commercialized and emerging materials, and add perspective on future areas of research. Currently, the leading magnetic material for EV motors is Nd 2 Fe 14 B, with samarium-cobalt compounds (SmCo 5 and Sm 2 Co 17 ) providing the only high-performing commercialized alternative. Emerging materials that address criticality concerns include Sm 2 Fe 17 N 3 , Fe 16 N 2 , and the L1 0 structure of FeNi, which use lower cost elements that produce similar magnetic properties. However, these temperature-sensitive materials are incompatible with current metallurgical processing techniques. We provide perspective on how advances in low-temperature synthesis and processing science could unlock new classes of high-performing magnetic materials for a paradigm shift beyond rare earth-based magnets. In doing so, we explore the question: What magnetic materials will drive future EVs? Graphical abstract

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Emerging magnetic materials for electric vehicle drive motors [Slides]

Increasing demand for electric vehicles (EVs) is increasing demand for the permanent magnets that drive their motors, as approximately 80% of modern EV drivetrains rely on high-performance permanent magnets to convert electricity into torque. In turn, these high-performance permanent magnets rely on rare earth elements for their magnetic properties. These elements are "critical" (i.e., at risk of limiting the growth of renewable energy technologies such as EVs), which motivates an exploration for alternative materials. In this article, we overview the relevant fundamentals of permanent magnets, describe commercialized and emerging materials, and add perspective on future areas of research. Currently, the leading magnetic material for EV motors is Nd 2 Fe 14 B, with samarium-cobalt compounds (SmCo 5 and Sm 2 Co 17 ) providing the only high-performing commercialized alternative. Emerging materials that address criticality concerns include Sm 2 Fe 17 N 3 , Fe 16 N 2 , and the L10 structure of FeNi, which use lower cost elements that produce similar magnetic properties. However, these temperature-sensitive materials are incompatible with current metallurgical processing techniques. We provide perspective on how advances in low-temperature synthesis and processing science could unlock new classes of high-performing magnetic materials for a paradigm shift beyond rare earth-based magnets. In doing so, we explore the question: What magnetic materials will drive future EVs?

42 ENGINEERING↗
DOE OSTI2018

Metal Amorphous Nanocomposite Soft Magnetic Material-Enabled High Power Density, Rare Earth Free Rotational Machines [Metal Amorphous Nanocomposite (MANC) Soft Magnetic Material (SMM) Enabled High Power Density, Rare Earth Free Rotational Machines]

Metal amorphous nanocomposites (MANCs) are promising soft magnetic materials (SMMs) for power electronic applications offering low power loss at high frequency and maintaining a relatively high flux density. While applications in certain motor designs have been recently modeled, their widespread application awaits scaled manufacturing of MANC materials and proliferation of new higher speed motor designs. A hybrid motor design based on permanent magnets and doubly salient stator and rotor is reported here to develop a compact (a factor of 10 smaller than currently possible in Si steels), high-speed (>1 kHz, electrical), high-power (>2.5 kW) motor by incorporating low loss (<10 W/kg at 1 kHz) MANCs such as recently reported Fe-Ni-based alloys. A feature of this motor design is flux focusing from the permanent magnet allowing use of lower energy permanent magnet chosen from among non-rare earth containing compositions and attractive due to constraints posed by rare earth criticality. A 2-D finite element analysis model reported here indicates that a 2.5 kW hybrid motor may be built with a permanent magnet with a 0.4 T remanence at a rotor speed of 6000 rpm. At a magnetic switching frequency of 1.4 kHz, the core loss may be limited to <3 W by selecting an appropriate MANC SMM. The projected efficiency exceeds 96% not including power loss in the controller. Under full load conditions, the flux density distributions for the SMM stay predominantly <1.3 T, the saturation magnetization of optimized FeNi-based MANC alloys. As a result, the maximum demagnetizing field in the permanent magnet is less than 2.2 × 10 5 A/m sustainable, for example, with a high-grade hard ferrite magnet.

42 ENGINEERING↗
DOE OSTI2018

Electro-dynamic machine, system and method

One embodiment is a unique Vernier machine comprising a rotor and a stator. The rotor comprises a back portion and a plurality of permanent magnets. The stator comprises a plurality of ferromagnetic arm structures, a plurality of ferromagnetic pole structures extending from each of the ferromagnetic arm structures in a direction toward the permanent magnets, and a plurality of conductive windings disposed about respective ones of the plurality of ferromagnetic arm structures. The ferromagnetic pole structures are structured to collect magnetic flux from the permanent magnets. The ferromagnetic pole structures of each of said ferromagnetic arm structures are spaced apart from one another according to a non-uniform pattern such that the ferromagnetic pole structures of a given ferromagnetic arm structure have substantially the same angular position relative to the permanent magnets radially opposite from the ferromagnetic pole structures of the given ferromagnetic arm structure.

42 ENGINEERING↗
DOE OSTI2020

Thermodynamics and Magnetism of YCo5 Compound Doped with Fe and Ni: An Ab Initio Study

YCo5 permanent magnet exhibits high uniaxial magnetocrystalline anisotropy energy and has a high Curie temperature. These are good properties for a permanent magnet, but YCo5 has a low energy product, which is notably insufficient for a permanent magnet. In order to improve the energy product in YCo5, we suggest replacing cobalt with iron, which has a much bigger magnetic moment. With a combination of density-functional-theory calculations and thermodynamic CALculation of PHAse Diagrams (CALPHAD) modeling, we show that a new magnet, YFe3(Ni1-xCox)2, is thermodynamically stable and exhibits an improved energy product without significant detrimental effects on the magnetocrystalline anisotropy energy or the Curie temperature.

anisotropy↗
DOE OSTI2015

Development of high-vacuum planar magnetron sputtering using an advanced magnetic field geometry

A permanent magnet in a new magnetic field geometry (namely, with the magnetization in the radial direction) was fabricated and used for high-vacuum planar magnetron sputtering using Penning discharge. Because of the development of this magnet, the discharge current and deposition rate were increased two to three times in comparison with the values attainable with a magnet in the conventional geometry. This improvement was because the available space for effective discharge of the energetic electrons for the ionization increased because the magnetic field distribution increased in both the axial and radial directions of discharge.

42 ENGINEERING↗
NASA NTRS1994

Permanent superconducting magnets for space applications

Work has been done to develop superconducting trapped field magnets (TFM's) and to apply them to a bumper-tether device for magnetic docking of spacecraft. The quality parameters for TFM's are J(c), the critical current of the superconductor, and d, the diameter of the superconducting tile. During this year we have doubled d, for production models, from 1 cm to 2 cm. This was done by means of seeding, an improved temperature profile in processing, and the addition of 1 percent Pt to the superconductor chemistry. Using these tiles we have set increasing records for the fields' permanent magnets. Magnets fabricated from old 1 cm tiles trapped 1.52 Tesla at 77K, 4.0T at 65K and 7.0T at 55K. The second of these fields broke a 17 year old record set at Stanford. The third field broke our own record. More recently using 2 cm tiles, we have trapped 2.3T at 77K, and 5.3T at 65K. We expect to trap lOT at 55K in this magnet in the near future. We have also achieved increases in J(c) using a method we developed for seeding U-235, and subsequently bombarding with neutrons. This method doubles J(c). We have not yet fabricated magnets from these tiles. During this year we have increased production yields from 15 percent to 95 percent. We have explored the properties of a magnetic bumper-tether for spacecraft. We have measured the bumper forces, and their dependence on time, distance, and the field of the ordinary ferromagnet (used together with a TFM). We have accounted for 85 percent of the collision energy, and its transformation to magnetic energy and heat energy. We have learned to control the relative bumper and tether forces by controlling TFM and ferromagnetic field strengths.

Weinstein, Roy↗
DOE OSTI2016

Conceptual design of a three-pole wiggler for the APS upgrade

The current design of the Advanced Photon Source Upgrade (APS-U) project is a multi-bend achromat (MBA) lattice, which incorporates three-pole wigglers as radiation sources for the bending magnet beamlines. They are located in the short section between the M4 dipole and Q8 quadrupole magnets. Due to space constraints, a hybrid permanent magnet design is necessary to provide the required magnetic field strength. A three-pole wiggler with a flat peak field profile along the beam axis was designed to enhance the photon flux and flatten the transverse flux density distributions. The magnetic peak field at the center pole reached 1.08 Tesla for a magnetic gap of 26 mm. The maximum power density, integrated over all vertical angles, is 3.1 W/mm{sup 2}, which is substantially higher than that of the existing bending magnets at the APS (0.86 W/mm{sup 2}). Detailed designs of the three-pole wiggler is presented, including calculated spectral-angular flux distributions.

43 PARTICLE ACCELERATORS↗
DOE OSTI2012

The new RF sources for accelerators

Several new RF sources are being developed for accelerator and collider applications. Assembly is nearing completion of a multiple beam inductive output tube at 352 MHz. An annular beam klystron is being developed to produce 10 MW pulses at 1.3 GHz. The annular beam approach provides significant cost reduction over similar multiple beam devices. Fabrication is underway on a 10 kW, periodic permanent magnet klystron at 2.815 GHz. Permanent magnets eliminate the solenoid and associated power supplies and cooling requirements to reduce operational cost. Investigations are beginning on a novel approach for driving accelerator cavities using pulse shaping to increase coupling efficiency and dramatically reduce RF power requirements.

43 PARTICLE ACCELERATORS↗
NASA NTRS1995

Aspects of passive magnetic levitation based on high-T(sub c) superconducting YBCO thin films

Passive magnetic levitation systems reported in the past were mostly confined to bulk superconducting materials. Here we present fundamental studies on magnetic levitation employing cylindrical permanent magnets floating above high-T(sub c) superconducting YBCO thin films (thickness about 0.3 mu m). Experiments included free floating rotating magnets as well as well-established flexible beam methods. By means of the latter, we investigated levitation and drag force hysteresis as well as magnetic stiffness properties of the superconductor-magnet arrangement. In the case of vertical motion of the magnet, characteristic high symmetry of repulsive (approaching) and attractive (withdrawing) branches of the pronounced force-displacement hysteresis could be detected. Achievable force levels were low as expected but sufficient for levitation of permanent magnets. With regard to magnetic stiffness, thin films proved to show stiffness-force ratios about one order of magnitude higher than bulk materials. Phenomenological models support the measurements. Regarding the magnetic hysteresis of the superconductor, the Irie-Yamafuji model was used for solving the equation of force balance in cylindrical coordinates allowing for a macroscopic description of the superconductor magnetization. This procedure provided good agreement with experimental levitation force and stiffness data during vertical motion. For the case of (lateral) drag force basic qualitative characteristics could be recovered, too. It is shown that models, based on simple asymmetric magnetization of the superconductor, describe well asymptotic transition of drag forces after the change of the magnet motion direction. Virgin curves (starting from equilibrium, i.e. symmetric magnetization) are approximated by a linear approach already reported in literature only. This paper shows that basic properties of superconducting thin films allow for their application to magnetic levitation or - without need of levitation forces, e.g. microgravity - magnetic damping devices.

Schoenhuber, P.↗
DOE OSTI2022

Design of an arrangement of cubic magnets for a quasi-axisymmetric stellarator experiment

The usage of permanent magnets to shape the confining field of a stellarator has the potential to reduce or eliminate the need for non-planar coils. As a proof-of-concept for this idea, we have developed a procedure for designing an array of cubic permanent magnets that works in tandem with a set of toroidal-field coils to confine a stellarator plasma. All of the magnets in the design are constrained to have identical geometry and one of three polarization types in order to simplify fabrication while still producing sufficient field accuracy. We present some of the key steps leading to the design, including the geometric arrangement of the magnets around the device, the procedure for optimizing the polarizations according to three allowable magnet types, and the choice of magnet types to be used. We apply these methods to design an array of rare-Earth permanent magnets that can be paired with a set of planar toroidal-field coils to confine a quasi-axisymmetric plasma with a toroidal magnetic field strength of about 0.5 T on axis.

Hammond, Kenneth↗
DOE OSTI2019

Trapped Field and Levitation Performance of a YBCO Superconductor Magnetized in Different External Magnetic Fields

In order to find a relative preferable method to improve the trapped magnetic field (B{sub trap}) of a YBCO superconductor, the influences of field-cooling height (FCH), magnetization intensity, and magnetization process on the trapped fields of the high temperature superconductor (HTS) magnetized in the magnetic fields of the permanent magnet guideway (PMG) and the superconducting magnet (SM) were both studied. In addition, the levitation forces of the bulk magnetized in the two different magnetic fields were also investigated in this paper. The experimental results showed that the maximum trapped field ratio (δ{sub trap}) of the bulk magnetized above the PMG attained the largest value, when the initial FCH was 30 mm. The remagnetization process was a preferable method to increase the B{sub trap}, in the case that the FCH was higher than 30 mm. When the exciting current (I{sub e}) of the SM was smaller than 15 A, the remagnetization process was an effective method to improve the B{sub trap}. The remagnetization performance of the bulk attained the saturation, under the condition that the I{sub e} was larger than 15 A. In the aspect of the levitation performance, it can be found that the decreasing amplitude of the force with the B{sub trap} became larger, when the levitation gap was lower. The force acted on the bulk increased with increasing the magnetic fields of the SM. Moreover, the results also indicated that the initial B{sub trap} was larger; the maximum levitation force (F{sub lmax}) became smaller. The magnetic hysteresis of the bulk was found to decrease with increasing the B{sub trap.}.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Electronic and magnetic properties of Si substituted Fe{sub 3}Ge

Using first principles calculations, we studied the effect of Si substitution in the hexagonal Fe{sub 3}Ge. We find the low temperature magnetic anisotropy in this system to be planar and originating mostly from the spin-orbit coupling in Fe-d states. Reduction of the unitcell volume reduces the magnitude of in-plane magnetic anisotropy, eventually turning it positive which reorients the magnetic moments to the axial direction. Substituting Ge with the smaller Si ions also increases the anisotropy, potentially enhancing the region of stability of the axial magnetization, which is beneficial for magnetic applications such as permanent magnets. Our experimental measurements on samples of Fe{sub 3}Ge{sub 1−x}Si{sub x} confirm these predictions and show that substitution of about 6% of the Ge with Si increases by approximately 35 K the temperature range over which anisotropy is uniaxial.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Adding Magnetization to the Eddy Current Approximation of Maxwell's Equations

The eddy current approximation to Maxwell's equation often omits terms associated with magnetization, removing permanent magnets from the domain of validity of the approximation. We show that adding these terms back into the eddy current approximation is relatively straightforward, and demonstrate this on using a simple material constitutive model.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1986

Finite element modelling of non-linear magnetic circuits using Cosmic NASTRAN

The general purpose Finite Element Program COSMIC NASTRAN currently has the ability to model magnetic circuits with constant permeablilities. An approach was developed which, through small modifications to the program, allows modelling of non-linear magnetic devices including soft magnetic materials, permanent magnets and coils. Use of the NASTRAN code resulted in output which can be used for subsequent mechanical analysis using a variation of the same computer model. Test problems were found to produce theoretically verifiable results.

Sheerer, T. J.↗
DOE OSTI2023

Room Temperature Electrorefining of Rare Earth Metals from End-of-use Nd-Fe-B Magnets

Recovering rare earth elements (REE) from used permanent magnets, which contains about 30 wt.% of rare earth elements, has been persistent technological challenge. Current recycling methods relies on pyrometallurgical or hydrometallurgical processes which are energy- and chemical- intensive and not economically and environmentally viable for rare earth containing magnets. Enabling efficient and simplistic recovery and refining of REEs contained in End-of-Use (EoU) products, such as Neodymium-Iron-Boron (Nd-Fe-B) based magnets will play an important and complementary role in the total supply of REEs in the future. We designed a new electrochemical method and demonstrated a room temperature one-pot process that concurrently separates and electroplates REE from commercial Nd-Fe-B magnets. By establishing selective oxidation and reductive potential as electrochemical control parameter along with electrochemically compatible non-aqueous electrolyte system, we demonstrated selective electroleaching of lanthanides (Nd and Preseodymium (Pr)) from anode and concurrent plating as alloy at Pt cathode. The morphological and chemical evolution of the Nd-Fe-B magnets during electroleaching reveals the electrochemical stimuli and rate of dissolution depends on microstructural complexities of the Nd-Fe-B magnet. The concomitant electroplating process leads to Nd-Pr based alloy which can be used as raw metallic alloy for manufacturing new permanent magnet and other devices. Our study demonstrates a scalable separation and refining methodology, based on widely available organic electrolyte system and without any consumptive chemical use, for selective lanthanide recovery from waste magnets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

High Speed Hybrid Reluctance Motor Utilizing Anisotropic Materials

With high cost and volatility driving continued efforts to decrease reliance on the critical heavy rare earth materials used in traction drive applications, General Motors developed three variants of heavy rare earth-free (HRE-free) electric motors. The variants focused on taking advantage of advanced magnet technologies and new rotor topologies to improve mechanical strength and achieve power targets. The three variants were a HRE-free permanent magnet reluctance motor, a synchronous reluctance motor utilizing small HRE-free permanent magnets, and an induction motor with inserted copper bars and cast aluminum end-rings. Motors were designed with the intent of primary or secondary traction applications, depending on the topology. Variant 1 achieved performance comparable to HRE-containing permanent magnet motors through optimized topology and validation of HRE-free magnets, focusing on achieving energy products and demagnetization resistance comparable to those of HRE-containing magnets. Demagnetization testing demonstrated the motor robustness to currents and temperatures exceeding expected vehicle conditions, a key challenge to the use of HRE-free magnets. The Variant 1 motor also showed the best capability of meeting the US Drive technology 2020 targets, due to the high power-density of the permanent magnet motor and the potential cost reductions enabled by the removal of heavy rare earth materials. Variant 2 exhibited high efficiency in high speed regions due to the low high-speed losses, an important consideration for secondary traction applications, and significantly thrifted on magnet mass to reduce cost. Variant 3 contained copper bars within the induction rotor to reduce losses compared to cast aluminum, while using cast aluminum end-rings to reduce the cost and mass of the rotor. Optimization of the Cu-Al interface were focused on, as the interface is prone to forming brittle intermetallic compounds during the casting process. Prototypes of each motor variant were built and tested for performance, mechanical strength, and demagnetization resistance (Variants 1 and 2 only), with torque and power resulting close to the predicted values.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2013

High damping properties of magnetic particles doped rubber composites at wide frequency

Highlights: ► A new kind of permanent magnetic rubber was prepared. ► The microstructure and magnetic properties were investigated. ► The mechanical and damping properties were discussed. ► The new material is expected to be an isolator material to a changed frequency. - Abstract: A new kind of rubber composite was prepared by doping SrFe{sub 12}O{sub 19} nanoparticles coated with silane coupling agents (Si-69) into nitrile butadiene rubber (NBR) matrix, which was characterized by the scanning electron microscopy and X-ray spectroscopy. The results showed that the SrFe{sub 12}O{sub 19} nanoparticles were well dispersed in rubber matrix. Furthermore, the mechanical and magnetic properties of the rubber composites were investigated, in which the high tensile strength (15.8 MPa) and high saturation magnetization (22.9 emu/g) were observed. What is more, the high loss factor of the rubber composites was also obtained in a wide frequency range (0–100 Hz) at high loading (80 phr). The result is attributed to that the permanent magnetic field in rubber nanocomposites can absorb shock energy. These results indicate that the new kind of permanent magnetic rubber is expected to be a smart isolator material, in which the isolator will be able to adapt to a changed frequency.

36 MATERIALS SCIENCE↗