SEARCH · Search NASA

Results for “Elemental imbalances”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

52 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS1984

Rotordynamic Analysis of the SSME Turbopumps Using Reduced Models

Alternative methods for the rotor-dynamic and sensitivity analysis of large rotor systems are examined. The methods are assessed for their ability to utilize accurate models of reduced size along with effective procedures for describing the dynamic behavior of the systems. Frequency response-based techniques are developed for determining the steady state response to imbalance of the space shuttle main engine (SSME) turbopumps and the related eigenvalue problem. The rotor and housing are represented by reduced receptances associated with their coupling points. The housing may be described by all of its normal modes within a frequency range of interest. The effects of truncated higher and lower modes are accounted for in an approximate manner. A procedure is described for determining the sensitivity of the coupling forces to changes in the coupling elements and rotor speed of the turbopump systems. In addition, an eigenvalue sensitivity analysis technique is adopted for application to the systems. Computer programs were developed for the numerical implementation of the impedance and eigenvalue sensitivity formulated in this study.

Noah, S. T.↗

NASA NTRS2010

High-Temperature Surface-Acoustic-Wave Transducer

Aircraft-engine rotating equipment usually operates at high temperature and stress. Non-invasive inspection of microcracks in those components poses a challenge for the non-destructive evaluation community. A low-profile ultrasonic guided wave sensor can detect cracks in situ. The key feature of the sensor is that it should withstand high temperatures and excite strong surface wave energy to inspect surface/subsurface cracks. As far as the innovators know at the time of this reporting, there is no existing sensor that is mounted to the rotor disks for crack inspection; the most often used technology includes fluorescent penetrant inspection or eddy-current probes for disassembled part inspection. An efficient, high-temperature, low-profile surface acoustic wave transducer design has been identified and tested for nondestructive evaluation of structures or materials. The development is a Sol-Gel bismuth titanate-based surface-acoustic-wave (SAW) sensor that can generate efficient surface acoustic waves for crack inspection. The produced sensor is very thin (submillimeter), and can generate surface waves up to 540 C. Finite element analysis of the SAW transducer design was performed to predict the sensor behavior, and experimental studies confirmed the results. One major uniqueness of the Sol-Gel bismuth titanate SAW sensor is that it is easy to implement to structures of various shapes. With a spray coating process, the sensor can be applied to surfaces of large curvatures. Second, the sensor is very thin (as a coating) and has very minimal effect on airflow or rotating equipment imbalance. Third, it can withstand temperatures up to 530 C, which is very useful for engine applications where high temperature is an issue.

Zhao, Xiaoliang↗

DOE OSTI2022

Performance Analysis of Speculative Parallel Adaptive Local Timestepping for Conservation Laws

Stable simulation of conservation laws, such as those used to model fluid dynamics and plasma physics applications, requires the satisfaction of the so-called Courant-Friedrichs-Lewy condition. By allowing regions of the mesh to advance with different timesteps that locally satisfy this stability constraint, significant work reduction can be attained when compared to a time integration scheme using a single timestep size. However, parallelizing this algorithm presents considerable difficulty. Since the stability condition depends on the state of the system, dependencies become dynamic and potentially non-local. In this article, we present an adaptive local timestepping algorithm using an optimistic (Timewarp-based) parallel discrete event simulation. We introduce waiting heuristics to limit misspeculation and a semi-static load balancing scheme to eliminate load imbalance as parts of the mesh require finer or coarser timesteps. Last, we outline an interface for separating the physics of the specific conservation law from the temporal integration allowing for productive adoption of our proposed algorithm. We present a misspeculation study for three conservation laws, demonstrating both the productivity of the local timestepping API, for which 74% of the lines of code are reused across different conservation laws, and the robustness of the waiting heuristics—at most 1.5% of element updates are rolled back. Our performance studies demonstrate up to a 2.8× speedup versus a baseline unoptimized local timestepping approach, a 4x improvement in per-node throughput compared to an MPI parallelization of synchronous timestepping, and scalability up to 3,072 cores on NERSC’s Cori Haswell partition.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Packaging a 650V/400A GaN Half-bridge Power Module with Ultra-low Parasitics for Electric Vehicle Drive Applications

This paper proposes a compact and efficient half-bridge power module with three 650 V / 150 A GaN dies in parallel. The power module incorporates a main power printed circuit board (PCB), an interface PCB, and a flex PCB to achieve low parasitics in both power loop and gate-side connection, resolving the issue of high parasitics typically encountered with wire bonding in high-current applications. Additionally, the interface PCB decouples the design constraints between the power loop and the gate loops. The proposed design is optimized with a vertical loop configuration to reduce power loop inductance through magnetic flux cancellation. Finite element analysis indicates that the power loop inductance is 0.58 nH at 100 MHz, while the maximum die junction temperature reaches 131 °C under an ambient temperature of 65 °C and a load current of 385 A. The proposed multi-piece PCB structure reduces the inductance of the drive circuit to minimize EMI and to mitigate false triggering. At the same time, it reduces impedance mismatches across different driver circuits, thereby achieving dynamic current sharing in multi-chip parallel configurations. Under simulation conditions of 400 V / 385 A, the current imbalance among chips was limited to 5 A. A 400 V / 385 A double-pulse test was conducted to experimentally validate the performance of the proposed power module.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Scaling hyporheic nitrogen cycling in large river alluvial aquifers

Research Element 1: Denitrification is a difficult flux to measure when fluxes are low and when the ecosystem is difficult to sample. These attributes describe Nyack floodplain, a large gravel-bedded aquifer adjacent to the Middle Fork Flathead River. Given that denitrification is simply respiration with nitrate as a terminal electron acceptor, we reasoned that N 2 production should negatively covary with oxygen respiration so long that oxygen is available. We sampled 16 wells 8 times throughout a year and analyzed these water samples on a membrane-inlet mass spectrometer for N 2 :Ar and O 2 . We fit multilevel models to N 2 :Ar as a function of dissolved oxygen. Within wells, there was no relationship between O 2 and N 2 :Ar. Among wells N 2 :Ar increased as O 2 declined. Based on the slope of this relationship, ~ -0.07, and estimated oxygen respiration in Nyack derived from prior studies, a possible range for denitrification is 0-8 mmol m -2 d -1 corresponding to a turnover rate for nitrate of 0-0.2/d. This estimated turnover rate is in the lower 20% of rates measured in the LINX 2 study, yet shows that even in a low nitrate (0.005 mmol/L) aquifer denitrification can be a substantial sink for dissolved N. Research Element 3 and 4: We developed a new theoretical approach to describe the relationship between water inflow, water outflow, and water age in porous media control volumes under dynamic flow conditions. Our approach had three distinct steps. First we described the application of well-established equations borrowed from Chemical Engineering to describe water age distributions in the hyporheic zone under steady state conditions. We published the associated results in the scientific journal PLOS ONE. Second, we developed a new theory ("flow spans") to describe how predicted steady-state water age distributions will respond to time varying imbalances in hyporheic discharge and recharge. Finally, we developed a proof-of-concept simulation model based on the new theory and used the model to examine the effects of flow regulation on a simulated river with characteristics representative of western U.S. montane rivers with expansive hyporheic zones.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2005

The Closure of the Ocean Mixed Layer Temperature Budget using Level-Coordinate Model Fields

Entrainment is an important element of the mixed layer mass, heat, and temperature budgets. Conventional procedures to estimate entrainment heat advection often do not permit the closure of heat and temperature budgets because of inaccuracies in its formulation. In this study a rigorous approach to evaluate the effect of entrainment using the output of a general circulation model (GCM) that does not have an explicit prognostic mixed layer model is described. The integral elements of the evaluation are 1) the rigorous estimates of the temperature difference between mixed layer water and entrained water at each horizontal grid point, 2) the formulation of the temperature difference such that the budget closes over a volume greater than one horizontal grid point, and 3) the apparent warming of the mixed layer during the mixed layer shoaling to account for the weak vertical temperature gradient within the mixed layer. This evaluation of entrainment heat advection is compared with the estimates by other commonly used ad hoc formulations by applying them in three regions: the north-central Pacific, the Kuroshio Extension, and the Nino-3 areas in the tropical Pacific. In all three areas the imbalance in the mixed layer temperature budget by the ad hoc estimates is significant, reaching a maximum of about 4 K yr(exp -1).

temperature gradient↗

NASA NTRS1992

Modeling radiation forces acting on TOPEX/Poseidon for precision orbit determination

Geodetic satellites such as GEOSAT, SPOT, ERS-1, and TOPEX/Poseidon require accurate orbital computations to support the scientific data they collect. Until recently, gravity field mismodeling was the major source of error in precise orbit definition. However, albedo and infrared re-radiation, and spacecraft thermal imbalances produce in combination no more than a 6-cm radial root-mean-square (RMS) error over a 10-day period. This requires the development of nonconservative force models that take the satellite's complex geometry, attitude, and surface properties into account. For TOPEX/Poseidon, a 'box-wing' satellite form was investigated that models the satellite as a combination of flat plates arranged in a box shape with a connected solar array. The nonconservative forces acting on each of the eight surfaces are computed independently, yielding vector accelerations which are summed to compute the total aggregate effect on the satellite center-of-mass. In order to test the validity of this concept, 'micro-models' based on finite element analysis of TOPEX/Poseidon were used to generate acceleration histories in a wide variety of orbit orientations. These profiles are then compared to the box-wing model. The results of these simulations and their implication on the ability to precisely model the TOPEX/Poseidon orbit are discussed.

Marshall, J. A.↗

NASA NTRS2018

PACE Technical Report Series, Volume 4: Cloud Retrievals in the PACE Mission: PACE Science Team Consensus Document

Earth is a complex dynamical system exhibiting continuous change in its atmosphere, ocean,and surface elements. Nearly all (99.97%) of the energy driving these systems is linked to the Sun. Measurements of reflected sunlight contain a unique signature of wavelength-specific scattering and absorption interactions occurring between incoming solar energy and atmospheric (molecules, aerosols,clouds) and surface features Clouds can affect significantly both shortwave and long wave radiation, depending on altitude/vertical structure, thermodynamic phase, and optical properties. Low, warm, and optically thick clouds predominantly have a cooling effect, while high, cold, optically thin clouds can cause warming by absorbing warmer radiation emitted from the surface and lower atmosphere.When the net difference between outgoing and incoming solar radiation is matched by the net infrared radiation emitted to space, the Earth's climate is in radiative balance. While radiative forcing components (GHGs, aerosols - direct and indirect) contribute to a net radiative imbalance, climate sensitivity is ultimately determined by the contribution of various system feed backs. The role of cloud feedback in a warming climate is currently the largest inter-model uncertainty in climate sensitivity and therefore in climate prediction [Bony and Dufresne 2005]. A comprehensive understanding of current cloud propertiesand dynamic/microphysical processes requires a global perspective from satellites.

Plankton, Aerosol, Cloud, ocean Ecosystem (PACE)↗

NASA NTRS2016

Atg12 Maintains Skeletal Integrity by Modulating Pro-Osteoclastogenic Signals and Chondrocyte Differentiation

Weightlessness and radiation, two unique elements of space, profoundly decreases bone mass. This bone loss is attributed to increased activity of bone-resorbing osteoclasts and functional changes in bone-forming osteoblasts, cells that give rise to mature osteocytes. Our long-term goal is to identify signaling pathways that may be targeted to mitigate bone loss in scenarios of space exploration, radiotherapy and accidental radiation exposure. We have previously shown that exposure of MLO-Y4 osteocyte-like cells to simulated space radiation (56Fe) increased the expression of the pro-osteoclastogenic gene rankl and decreased protein levels of LC3B-II, a key player in autophagy. In this current study, we aimed to further elucidate the role of autophagy in maintaining structural integrity of the skeleton. We hypothesize that loss of autophagy in bone leads to an imbalance in pro-osteoclastogenic and pro-osteogenic signals, resulting in net bone loss. To test our hypothesis we performed global postnatal deletion of Atg12 using tamoxifeninducible Cre recombinase under the control of the CAG promoter. Six-week-old CAGCreERT2/ FloxAtg12 animals were treated daily with Tamoxifen or Vehicle (Control, oil only) for five days and euthanasia performed two weeks after the onset of treatment. Percent change in body weights (prior to treatment and at euthanasia) was not significantly different between treatment groups within the same gender. Compared to Vehicle (Control) groups, Tamoxifen (Atg12 iKO) groups showed decreased LC3B-I to II conversion and increased p62 protein levels, consistent with loss of autophagy. Quantitative PCR revealed increased expression of proosteoclastogenic cytokines mcp1 and rankl in bone and marrow respectively in male iKOs compared to male controls. Expression levels of these genes were not significantly altered in the Atg12 iKO females compared to females controls. Microcomputed tomography of tibiae revealed decreased cortical bone volume, cortical thickness and periosteal perimeter consistent with bone loss; and a longer primary spongiosa in male Atg12 iKOs display compared to male controls. These decrements were less pronounced in the female Atg12 iKOs. Cancellous bone structure was not significantly different between iKOs and controls in both genders. Histological analysis also revealed that compared to male controls, male iKOs showed a profound increase in chondrocyte column length of the growth plate with hyper-expansion of both proliferating and hypertrophic zones. Taken together, these findings indicate that autophagy plays an important role in the maintenance of bone structural integrity by mediating the production of proosteoclastogenic signals and regulating chondrocyte proliferation and differentiation.

autophagy↗

NASA NTRS2006

Integrated Modeling of Advanced Opto-Mechanical Systems

The design of optical hardware for space applications is particularly challenging when developing high performance, novel systems that have no precedent. Integrated modeling and analysis of such opto-mechanical systems seeks to describe the end-to-end performance of the hardware using mission-relevant metrics. This multidisciplinary analysis might start with thermal disturbances from observation maneuvers, compute the system temperatures, compute the distorted positions and shapes of the hardware and compute the resulting optical performance. Dynamic disturbances such as reaction wheel imbalance or inertia imbalance of optical delay lines might be applied to a structural dynamic model and used in a guidance and control analysis. Mission-relevant science metrics might include wavefront quality, pointing error or imaging stability. Assembling a tool chain that can be both nimble and effective when scaled to the high fidelity models of detail design has been challenging. An integrated thermal, mechanical and optical analysis capability suitable for detail design has been developed and verified through experimental measurement. This capability was used in the design of flight-like breadboard hardware and development of a test apparatus that established both the level of performance of the hardware and the validity of the analysis. The analysis includes prediction of the thermal environment of the test chamber, detailed temperature distributions on the breadboard hardware, fine scale deformations of the optical elements, and computation of the wavefront quality using geometric optics. A battery of tests were conducted to assess the experiment data acquisition, measurement and control system and to establish the performance of the hardware design and accuracy of the integrated modeling. Thermal loads that represent operational observing maneuvers were imposed and the hardware optical performance was measured and compared to analytical predictions.

optomechanical analysis↗

NASA NTRS2003

Methods Developed by the Tools for Engine Diagnostics Task to Monitor and Predict Rotor Damage in Real Time

Tools for Engine Diagnostics is a major task in the Propulsion System Health Management area of the Single Aircraft Accident Prevention project under NASA s Aviation Safety Program. The major goal of the Aviation Safety Program is to reduce fatal aircraft accidents by 80 percent within 10 years and by 90 percent within 25 years. The goal of the Propulsion System Health Management area is to eliminate propulsion system malfunctions as a primary or contributing factor to the cause of aircraft accidents. The purpose of Tools for Engine Diagnostics, a 2-yr-old task, is to establish and improve tools for engine diagnostics and prognostics that measure the deformation and damage of rotating engine components at the ground level and that perform intermittent or continuous monitoring on the engine wing. In this work, nondestructive-evaluation- (NDE-) based technology is combined with model-dependent disk spin experimental simulation systems, like finite element modeling (FEM) and modal norms, to monitor and predict rotor damage in real time. Fracture mechanics time-dependent fatigue crack growth and damage-mechanics-based life estimation are being developed, and their potential use investigated. In addition, wireless eddy current and advanced acoustics are being developed for on-wing and just-in-time NDE engine inspection to provide deeper access and higher sensitivity to extend on-wing capabilities and improve inspection readiness. In the long run, these methods could establish a base for prognostic sensing while an engine is running, without any overt actions, like inspections. This damage-detection strategy includes experimentally acquired vibration-, eddy-current- and capacitance-based displacement measurements and analytically computed FEM-, modal norms-, and conventional rotordynamics-based models of well-defined damages and critical mass imbalances in rotating disks and rotors.

Baaklini, George Y.↗

DOE OSTI2026

Back-to-back dijet production in DIS at arbitrary Bjorken x: TMD gluon distributions to twist-3 accuracy

We derive the gluon transverse-momentum-dependent (TMD) operator structure of back-to-back\\\\r\\\\nquark–antiquark dijet production in deep inelastic scattering at arbitrary Bjorken-x to twist-3 ac\\\\r\\\\ncuracy. Working at leading order in the strong coupling and in the kinematic regime where the\\\\r\\\\ntransverse momentum imbalance of the jets is much smaller than their individual transverse mo\\\\r\\\\nmenta, we perform a systematic gradient expansion of the quark propagator in a background gluon\\\\r\\\\nfield. This expansion organizes multiple interactions with the target in terms of longitudinal Wilson\\\\r\\\\nlines and gauge-invariant field-strength insertions, yielding a TMD description valid beyond the\\\\r\\\\nstrict high-energy eikonal (x → 0) approximation. We obtain explicit cross sections for longitudi\\\\r\\\\nnally and transversely polarized virtual photons, identifying all contributing gluon TMD operators\\\\r\\\\nup to twist-3, including structures involving F+−, Fij, and three-gluon correlators. The full lon\\\\r\\\\ngitudinal phase eixP+z− associated with Bjorken-x is retained throughout. In the small-x limit,\\\\r\\\\nour results reproduce the known sub-eikonal expressions obtained in the Color Glass Condensate\\\\r\\\\nframework, establishing a direct connection between the general-x TMD expansion and high-energy\\\\r\\\\nfactorization. We further reduce the operator basis using equations of motion, minimizing the num\\\\r\\\\nber of independent nonperturbative matrix elements entering the cross section. This work provides\\\\r\\\\na systematic foundation for extending TMD analyses of dijet production beyond leading twist, es\\\\r\\\\ntablishing a unified operator framework valid at arbitrary Bjorken-x that smoothly interpolates\\\\r\\\\nbetween moderate- and small-x descriptions of gluon TMDs.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2019

A Giant Impact as the Likely Origin of Different Twins in the Kepler-107 Exoplanet System

Measures of exoplanet bulk densities indicate that small exoplanets with radius less than 3 Earth radii (R(sub ⊕)) range from low-density sub-Neptunes containing volatile elements to higher-density rocky planets with Earth-like or iron-rich (Mercury-like) compositions. Such astonishing diversity in observed small exoplanet compositions may be the product of different initial conditions of the planet-formation process or different evolutionary paths that altered the planetary properties after formation. Planet evolution may be especially affected by either photoevaporative mass loss induced by high stellar X-ray and extreme ultraviolet (XUV) flux or giant impacts. Although there is some evidence for the former, there are no unambiguous findings so far about the occurrence of giant impacts in an exoplanet system. Here, we characterize the two innermost planets of the compact and near-resonant system Kepler-107 (ref. 9). We show that they have nearly identical radii (about 1.5–1.6R(sub ⊕)), but the outer planet Kepler-107 c is more than twice as dense (about 12.6 g cm–3) as the innermost Kepler-107 b (about 5.3 g cm−3). In consequence, Kepler-107 c must have a larger iron core fraction than Kepler-107 b. This imbalance cannot be explained by the stellar XUV irradiation, which would conversely make the more-irradiated and less-massive planet Kepler-107 b denser than Kepler-107 c. Instead, the dissimilar densities are consistent with a giant impact event on Kepler-107 c that would have stripped off part of its silicate mantle. This hypothesis is supported by theoretical predictions from collisional mantle stripping, which match the mass and radius of Kepler-107 c.

Bonomo, Aldo S.↗

DOE OSTI2026

Rare Earth Production in the United States: A Concise Review of Resource Development and Commercial Processes

This review article presents a concise review of estimated resources, processing methods and challenges involved in domestic rare earth mining projects in the United States (US). It also highlights the current status of major mining projects, anticipated rare earth production in the near future, and commercial projects utilizing non-traditional feedstocks for rare earth production and recycling. Based on the current industry outlook, opportunities for R&D have also been highlighted. Perspective on domestic rare earth production capability is essential because global rare earth production is currently dominated by China. Given potential export controls by China, this imbalance has created supply chain risk. The US and other countries have limited rare earth production capacity and relatively little expertise in rare earth processing. However, in the last decade, efforts have been made by several nations, including the US, to reduce their reliance on China for rare earth and other critical minerals. The US is currently investing in projects to develop domestic rare earth separation and refining capacity. These projects are discussed here. When backed by R&D and government support, these projects have potential to make significant progress towards establishment of domestic rare earth separation capabilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1999

Radar Interferometry Studies of the Mass Balance of Polar Ice Sheets

The objectives of this work are to determine the current state of mass balance of the Greenland and Antarctic Ice Sheets. Our approach combines different techniques, which include satellite synthetic-aperture radar interferometry (InSAR), radar and laser altimetry, radar ice sounding, and finite-element modeling. In Greenland, we found that 3.5 times more ice flows out of the northern part of the Greenland Ice Sheet than previously accounted for. The discrepancy between current and past estimates is explained by extensive basal melting of the glacier floating sections in the proximity of the grounding line where the glacier detaches from its bed and becomes afloat in the ocean. The inferred basal melt rates are very large, which means that the glaciers are very sensitive to changes in ocean conditions. Currently, it appears that the northern Greenland glaciers discharge more ice than is being accumulated in the deep interior, and hence are thinning. Studies of temporal changes in grounding line position using InSAR confirm the state of retreat of northern glaciers and suggest that thinning is concentrated at the lower elevations. Ongoing work along the coast of East Greenland reveals an even larger mass deficit for eastern Greenland glaciers, with thinning affecting the deep interior of the ice sheet. In Antarctica, we found that glaciers flowing into a large ice shelf system, such as the Ronne Ice Shelf in the Weddell Sea, exhibit an ice discharge in remarkable agreement with mass accumulation in the interior, and the glacier grounding line positions do not migrate with time. Glaciers flowing rapidly into the Amudsen Sea, unrestrained by a major ice shelf, are in contrast discharging more ice than required to maintain a state of mass balance and are thinning quite rapidly near the coast. The grounding line of Pine Island glacier (see diagram) retreated 5 km in 4 years, which corresponds to a glacier thinning rate of 3.5 m/yr. Mass imbalance is even more negative on Thwaites Glacier. This sector of West Antarctica probably initiated its collapse decades or centuries ago, once the embaying ice shelves in front of them started to melt because of enhanced basal melting from warmer ocean waters. Additional information is contained in the original.

Rignot, Eric↗

DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗