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NASA NTRSDate not supplied

Risk Reduction Testing of Superconducting Coils for the High Efficiency Megawatt Motor

Second generation high temperature superconducting coils provide a very attractive level of performance for use in the field winding of electric machines for aircraft. Aside from maintaining these coils at cryogenic temperatures, much care must be taken to prevent damaging these relatively fragile materials due to excessive stress. Thermal stresses due to temperature cycling and mechanical stresses due to centrifugal forces are the most critical for the High Efficiency Megawatt Motor. This paper summarizes two test campaigns that were undertaken to reduce the risks posed by these loads. In one campaign, several superconducting coils were fabricated, thermally cycled up to 50~times, and electrically tested in liquid nitrogen to assess the change in superconductivity metrics throughout thermal cycling. In the other campaign, a full-scale superconducting coil was fabricated, a test article was designed to produce a representative stress environment in the coil, the test article and coil were rotated at room temperature up to a speed of 11,800~rpm, and the superconductivity metrics were measured in liquid nitrogen before and after each rotation. The experimental results demonstrate that the superconducting coils manufactured in house can survive both thermal cycling and high speed rotation with no appreciable degradation in superconducting performance.

partially superconducting electric machine↗

NASA NTRSDate not supplied

Lessons Learned From A Cryogenic Motor Configuration Study for Aircraft Propulsion

Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Superconducting stators that make use of low AC loss superconducting wires are considered to be a key component for these cryogenic machines. NASA has undertaken 6-year technical challenge to address this need by designing a 5 MW superconducting motor and cryogenic drive and developing multi-MW prototypes. This poster shares the lessons learned from a completed design study that evaluated several configurations of a 5 MW cryogenic motor for this application. The lessons are drawn from a qualitative study of 16 configurations and a quantitative study of 8 down selected configurations. The quantitative study involved using a motor design code based on analytical calculations (electromagnetic, thermofluid, mechanical, and motor sizing) to determine each configuration’s Pareto front of total efficiency and total specific power. This poster builds upon preliminary results that were previously presented by (1) reporting final results based on a revised design code for each configuration, including a considerable increase in fidelity for a novel radial flux motor and (2) making a down selection of the configuration for future detailed design and demonstration and documenting the rationale for the selection.

Superconductors↗

NASA NTRSDate not supplied

Conclusions of a Cryogenic Motor Configuration Study for Aircraft Propulsion

Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Superconducting stators that make use of low AC loss superconducting wires are considered to be a key component for these cryogenic machines. This paper shares the lessons learned from a design study that evaluated several configurations of a 5 MW cryogenic motor for this application. The lessons are drawn from a qualitative study of 16 configurations and a quantitative study of 8 down selected configurations. The quantitative study involved using analytical calculations (electromagnetic, thermofluid, mechanical, and motor sizing) to determine each configuration’s Pareto front of total efficiency and total specific power. The conclusions from a preliminary assessment of different stator conductors (superconductors and cryogenic metals) are also presented. One motor configuration is down selected for future detailed design and demonstration at the multi megawatt level.

Electrified aircraft propulsion↗

NASA NTRS2021

Center for High-Efficiency Electrical Technologies for Aircraft (CHEETA)

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. With subsonic transports serving as the dominant contributor to the fuel consumption and carbon footprint of global aviation, the need for environmentally-responsible transportation has been met with a boom of research in the field of aircraft propulsion electrification across industry, government, and academic organizations. However, adoption of electrified propulsion systems for large commercial aircraft today is unattainable, due to the lack of motors and power electronics appropriately sized for these vehicles, high weight requirements of conventional electrical energy storage systems, and new principles required to design these classes of aircraft. The mission of the Center for High-Efficiency Electrical Technologies for Aircraft (CHEETA) program is to develop, mature, and design disruptive technologies for electric commercial aviation. The associated technologies being researched include distributed aero-propulsion system integration, high-efficiency electrochemical power conversion, flight-weight electric machines and power electronics, materials and systems for superconducting high-efficiency power transmission, and methods for complex system integration and optimization. Additionally, the current program is investigating the use of unconventional energy storage and power generation architectures, such as liquid hydrogen fuel and high-efficiency fuel cell systems. The research program provides a direct line-of-sight to not only achieving, but potentially even exceeding the aviation community goals for transition to alternative propulsion and energy through convergence of various novel technologies. The end result of maturation and integration of these technologies is an aircraft system with a quiet, efficient propulsion system that produces zero carbon dioxide, nitrogen oxides, and particulate matter emissions at the vehicle level.

Koushik Datta↗

NASA NTRS2018

Preliminary Design of the Superconducting Rotor for NASA's High-Efficiency Megawatt Motor

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. The design of the superconducting rotor and the optimization of its electromagnetic and structural responses are analyzed in this paper. Candidate designs are evaluated in terms of absolute performance, specific performance, and performance per cost. It is found that optimizing the electromagnetic response for absolute or specific performance yields designs that are similar to each other, but opposite of the cost-optimized design. A method to define the thermal requirements of the superconducting coils and integrated cryocooler is also presented.

electric machines↗

NASA NTRS2018

Design, Fabrication, and Critical Current Testing of No-Insulation Superconducting Rotor Coils for NASA's 1.4 MW High-Efficiency Megawatt Motor

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 discusses the design and fabrication of the no-insulation high temperature superconducting (HTS) rotor coils and compares them to conventionally insulated HTS coils. Two sub-scale test coils with epoxy on only one axial face were fabricated. Critical current testing of the coils at 77 K and self field was conducted to study the influence of thermal cycling on their critical current and n-value. After two or four aggressive thermal cycles between 77 K and about 278 K (5 degree C), the critical current and n-value were nearly unchanged, indicating very little to no degradation.

electric aircraft propulsion↗

NASA NTRS2019

New Test Rig to Measure Alternating Current Losses of Both Low and High Critical Temperature Superconductors

This paper presents the design, development, operation, and test capabilities of a proposed superconducting coil testbed to measure alternating current (AC) losses at the NASA Glenn Research Center. Superconducting AC losses are important in the design of electric stators and rotors, power transmission lines, transformers, fault current limiters, magnets, and superconducting energy storage (not batteries). The new liquid-hydrogen-based rig will allow superconducting testing across a wide range of test parameters, including injected current up to 400 A, frequency (0 to 400 Hz), magnetic field (0 to 0.6 T), phase angle between induced voltage and injected current (–180° to 180°), coil coolant temperature (18 to 28 K), and AC power loss (5 to 30 W). While the target application of interest is 20 K superconducting MgB2 (the only superconductor that can presently be made with low losses) stator coils for future electric machines, the rig can accommodate test articles (TAs) with straight wire, tape, cables, coils of any shape, any allowable combination of superconducting wire and fluid (e.g., yttrium barium copper oxide (YBCO) coils and liquid nitrogen), and AC or direct current (DC) testing. The new spin rig builds upon the existing Air Force spin rig through a more flexible mode of fluid control, a wider gap space (up to 10.2 cm) for TAs, and the ability to accommodate TAs over a wider range of operating temperatures (18 to 95 K) using liquid hydrogen, gaseous helium, or liquid nitrogen as the working fluid, thus supporting direct cooled machines below 77 K.

liquid hydrogen↗

NASA NTRS2018

Preliminary Design of the Superconducting Rotor for NASA's High-Efficiency Megawatt Motor

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. The design of the superconducting rotor and the optimization of its electromagnetic and structural responses are analyzed in this paper. Candidate designs are evaluated in terms of absolute performance, specific performance, and performance per cost. It is found that optimizing the electromagnetic response for absolute or specific performance yields designs that are similar to each other, but opposite of the cost-optimized design. A method to define the thermal requirements of the superconducting coils and integrated cryocooler is also presented.

Scheidler, Justin↗

NASA NTRS2023

Concept Design for a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN hybrid electric flight concept. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor (HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico↗

NASA NTRS2018

Design, Fabrication, and Critical Current Testing of No-Insulation Superconducting Rotor Coils for NASA's High-Efficiency Megawatt Motor

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 discusses the fabrication of the no-insulation high temperature superconducting (HTS) coils and presents the lessons learned. The process is compared to the fabrication of conventionally insulated HTS coils. Testing of the coils' critical current at liquid nitrogen temperature is also presented. The influence of thermal cycling on the critical current and n-value is studied.

Scheidler, Justin J.↗

NASA NTRS2023

Concept Design of a 5 MW Partially Superconducting Generator

This paper presents a concept design for the 5 MW generators on NASA’s SUSAN electric flight demonstrator concept vehicle. The performance targets for this machine are 25 kW/kg and 99% efficiency. The concept design is a partially superconducting machine that builds on NASA’s past work on its High Efficiency Megawatt Motor(HEMM). A partially superconducting machine design tool is used to create a preliminary concept design capable of achieving the target specifications for the SUSAN generator. Higher fidelity design and analysis is applied to the preliminary design. After high fidelity analysis the machine is predicted to achieve 22.3 kW/kg and 99.1% efficiency. Lessons learned from this concept design will be incorporated in the next iteration of the machine.

Thomas Tallerico↗

NASA NTRS1972

Applied Superconductivity Conference, 5th, Annapolis, Md., May 1-3, 1972, Proceedings.

Recently developed practical applications of superconductivity are described in papers dealing with transportation and propulsion, power generation, power transmission, special-purpose magnets, superconducting materials, Josephson junctions, and microwave systems. Important topics considered include tracked magnetic-cushion vehicles, electrical machines, cryogenic underground power transmission systems, magnets for fusion reactors and particle accelerators, thin-film superconductors, effects of the structural characteristics of materials on transition temperatures, frequency measurement with Josephson devices, and superconducting scientific instruments. Individual items are announced in this issue.

Source record↗

DOE OSTI2025

Flux-Switching Machine Based All-Electric Power Train for Future Aircraft

This research investigates a flux-switching motor with superconducting and cryogenically cooled windings, aimed at achieving exceptionally high power densities. In addition to the motor’s topology and superconducting windings, it was found that power density could be further enhanced by incorporating superconducting shields on the rotor at the interpole locations. The resulting publications and patented technology outline the design process. A motor power density of 64 kW/kg—including housing materials—was achieved for a 1 MW design, surpassing the performance of existing motors. An electronic drive was also developed, achieving a power density of 47 kW/kg. This includes the mechanical structure of the drivetrain, for which a detailed CAD model was created, resulting in an overall drivetrain power density of 27 kW/kg.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Design of a 915 MHz conduction-cooled cryomodule

High-power, compact, continuous-wave (CW) linear electron accelerators with beam energies of up to 10 MeV are being considered for possible industrial applications. Conduction-cooled, superconducting radio-frequency (SRF) technology allows operating such machines at high electrical efficiency, thereby reducing the operating cost significantly. A prototype conduction-cooled SRF cryomodule has been designed and components are currently being manufactured. The cryomodule features a two-cell, 915 MHz SRF cavity, two cryocoolers, a fundamental power coupler, two magnetic shields, a thermal shield and warm-to-cold transitions. The cryomodule has been designed to be able to provide an energy gain of 3.5 MeV to a CW electron beam with a current of 5 mA. This contribution focusses on thermal and mechanical design aspects of the cryomodule.

Ciovati, G. [Old Dominion Univ., Norfolk, VA (Unit↗

DOE OSTI2025

Design of a 915 MHz conduction-cooled cryomodule

Ciovati, G. [Old Dominion Univ., Norfolk, VA (Unit↗

DOE OSTI2024

Cost-effective Conductor, Cable, and Coils for High Field Rotating Electric Machines

The purpose of the DOE-AMMTO-funded project was to significantly reduce industrial energy intensity through manufacturing innovations. The project focused on superconducting technology for industrial motors to dramatically increase efficiency. The bottleneck in deploying high temperature superconducting (HTS) motors was high cost and low yield of the conductor manufacturing process. The process yield is low because of the defects in the conductor, forcing the manufacturers to cut off defective sections after characterizing each millimeter. Additionally, the piece lengths tend to be low because of the defects. The project tackled the low-yield manufacturing process challenge by devising an innovative method to use defective conductors in bundled cables without losing performance by engineering current sharing among the conductors. The innovation not only lowers the cost of the conductor but also enhances the reliability of HTS motors and other devices to mitigate the defects that might form during the fabrication and operation of the device. With the increasing interest in REBa2Cu3O7-x (REBCO)-coated conductors for various power, energy, and magnet applications, ensuring the reliability of HTS devices is of significant interest. The EERE funding allowed us to make significant progress in understanding the defects in manufactured conductors and the implications of the defects in superconducting electric motors and other superconducting power and energy applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Concept Design of a 1.4 MW Drive for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near-term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5% efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Cryogenic↗

NASA NTRSDate not supplied

Concept Design a 1.4 MW Inverter for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Concept design↗