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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Unraveling Site Selective Magnetic Properties of Cobalt Sites in Critical Elements Lean RE(TM)5 Magnet Materials

We report here our discovery of crystallographic and interstitial sites and onsite electron correlation propelled intrinsic and derived permanent magnetic properties of critical elements lean RE(TM) 5 (RE = La, Ce and TM = Fe, Co) magnet materials. A full potential linearized augmented plane wave (FP-LAPW) method within the local density approximation (LDA) is used to investigate and analyze the electronic structure and magnetism of these RE(TM) 5 type structures. To better correlate the experimental results, the effective Coulomb (U) and exchange (J) interactions (Hubbard parameters) are crucial at the transition metal sites. Results show that the main propeller of magnetic anisotropy in these compounds is the cobalt atoms at the 2c sites not the 3g sites. This site-specific property and site preference energetics are used to replace 3g sites with non-critical elements such as iron that exhibits a larger magnetic moment. Based on this strategic replacement, we predict two new compounds that have a larger hardness parameter with a relatively large energy product due to the atomic dilution caused by interstitial addition of nitrogen in the compounds: CeCo 2 Fe 3 N 2 and LaCo 2 Fe 3 N 2 .

Rare-earths↗
DOE OSTI2019

Preparation and Characterization of NdFeB/PrCo{sub 5} Nanocomposite Magnetic Materials

We first developed NdFeB/PrCo{sub 5} nanocomposite magnetic material by high-energy ball milling, and the influence of the different contents of PrCo{sub 5} on the magnetic properties of NdFeB was studied by means of XRD, DSC, and VSM. The results showed that compared with single-phase NdFeB permanent-magnet material, NdFeB/PrCo{sub 5} nanocomposite magnetic material has superior magnetic properties. When the content of PrCo{sub 5} is 10% and the time of ball milling is 10 h, the magnetic properties for NdFeB/PrCo{sub 5} nanocomposite magnetic material is best: coercivity is 13.2 kOe, which increased by 14.8% over pure NdFeB phase. Remanent magnetization is 96.31 emu/g and the saturation magnetization is 132.29 emu/g. The remanence ratio is 0.728.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Giant Magnetic and Optical Anisotropy in Cerium-Substituted M-Type Strontium Hexaferrite Driven by $4f$ Electrons

By performing density-functional calculations, we find a giant magnetocrystalline anisotropy (MCA) constant in abundant element cerium $\mathrm{Ce}$ substituted M-type hexaferrite, in the energetically favorable strontium site, assisted by a quantum confined electron transfer from $\mathrm{Ce}$ to a specific iron $\mathrm{2a}$ site. Remarkably, the calculated electronic structure shows that the electron transfer leads to the formation of $\mathrm{Ce}^{3+}$ and $\mathrm{Fe}^{2+}$ at the $\mathrm{2a}$ site producing an occupied $\mathrm{Ce}$$(4f^1)$ state below the Fermi level that adds a significant contribution to MCA and magnetic moment. A half $\mathrm{Ce}$ substitution forms a metallic state, while a full substitution retains the semiconducting state of the strontium hexaferrite (host). In the latter, the band gap is reduced due to the formation of charge-transferred states in the gap region of the host. The optical absorption coefficient shows an enhanced anisotropy between light polarization in parallel and perpendicular directions. Calculated formation energies, including the analysis of probable competing phases, and elastic constants confirm that both compositions are chemically and mechanically stable. With successful synthesis, the $\mathrm{Ce}$ hexaferrite can be an alternative high-performing critical-element-free permanent magnet material adapted for use in devices such as automotive traction drive motors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

MnBi-based magnets prepared from melt-spun alloys: Effect of $α → β$ phase transformation during field annealing

The temperature of the annealing treatment applied to the MnBi alloys with the intention to stabilize the α -MnBi “low-temperature” phase – a promising material for the rare-earth-free permanent magnets – is usually kept below the range of the β -Mn 1.08 Bi “high-temperature” phase. This work is focused on the investigation of the effects of partial and complete α → β phase transformation in bulk magnetic-field-annealed magnets on their structure and magnetic properties. MnBi alloys modified with In, Mg and Sb were melt-spun, compacted to their full density and then heated in a magnetic field of 30 kOe to temperatures sufficiently high for the beginning of the α → β transformation. A heating of 15 °C/min was used which was immediately followed by cooling at the rate of 7.5 °C/min; the degree of the phase transformation was measured by in situ monitoring of changes in the sample magnetization. In all the studied alloys, the α → β transformation was found to improve the [0 0 1] fiber texture induced by the applied magnetic field, although it simultaneously decreased the coercivity. A partial transformation has resulted in a 11% increase of the maximum energy product for the Mn 50 Bi 49 Sb 0.5 In 0.5 magnet, to 8.3 MGOe, and a 3% increase for the Mn 50 Bi 46 Mg 3 Sb 0.5 In 0.5 magnet, to 12.8 MGOe. In the latter alloy, the α → β and reverse transformations were found to initially occur in well-defined pockets leading to clusters of large, highly textured α crystallites. In the Mn 50 Bi 48.5 Sb 1.5 magnet, only part of the α phase could be recovered after the transformation, which instead promoted the paramagnetic MnBi 0.9 Sb 0.1 phase.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Non-magnetic organic/inorganic spin injector at room temperature

Spin injection into solid-state devices is commonly performed by use of ferromagnetic metal electrodes. Here, we present a spin injector design without permanent magnet; rather, the spin selectivity is determined by a chiral tunneling barrier. The chiral tunneling barrier is composed of an ultrathin Al{sub 2}O{sub 3} layer that is deposited on top of a chiral self-assembled monolayer (SAM), which consists of cysteine or oligopeptide molecules. The experimentally observed magnetoresistance can be up to 20% at room temperature, and it displays an uncommon asymmetric curve as a function of the applied magnetic field. These findings show that the spin injector transmits only one spin orientation, independent of external magnetic field. The sign of the magnetoresistance depends on the handedness of the molecules in the SAM, which act as a spin filter, and the magnitude of the magnetoresistance depends only weakly on temperature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Beyond 15 MW: A cost of energy perspective on the next generation of drivetrain technologies for offshore wind turbines

Leading wind turbine manufacturers are racing to build larger and more powerful offshore machines. Drivetrain configurations often use a permanent-magnet synchronous generator (PMSG), in either a direct-drive configuration or coupled to a gearbox. With increasing demand for critical rare-earth magnets, new generator technologies are emerging to ensure a stable and secure supply chain. We evaluate three different topologies of radial flux synchronous generators employing high field magnets with reduced or no rare-earth content: a direct-drive interior PMSG (DD-IPMSG), a geared drivetrain combining a medium speed gearbox with a PMSG (MS-PMSG), and a direct-drive low-temperature superconducting generator (DD-LTSG). We develop a conceptual design module for each of these technologies within a larger framework for full turbine design. This provides the fairest comparison between technologies at nominal power ratings from 15-25 MW, which represent the next generation of offshore wind turbines. The analyses show that if operational expenditures (OpEx) are constant across the technologies, MS-PMSG results in the lowest LCOE with reductions of up to 7% relative to DD-IPMSG. DD-LTSG also yields lower LCOE values by 2%-3% for fixed-bottom turbines and 3%-5% with a floating platform. However, results are sensitive to OpEx assumptions, with a mere 10% increase causing the conclusions to shift.

17 WIND ENERGY↗
DOE OSTI2014

A compact high-performance low-field NMR apparatus for measurements on fluids at very high pressures and temperatures

We discuss an innovative new high-performance apparatus for performing low-field Nuclear Magnetic Resonance (NMR) relaxation times and diffusion measurements on fluids at very high pressures and high temperatures. The apparatus sensor design and electronics specifications allow for dual deployment either in a fluid sampling well logging tool or in a laboratory. The sensor and electronics were designed to function in both environments. This paper discusses the use of the apparatus in a laboratory environment. The operating temperature and pressure limits, and the signal-to-noise ratio (SNR) of the new system exceed by a very wide margin what is currently possible. This major breakthrough was made possible by a revolutionary new sensor design that breaks many of the rules of conventional high pressure NMR sensor design. A metallic sample holder capable of operating at high pressures and temperatures is provided to contain the fluid under study. The sample holder has been successfully tested for operation up to 36 Kpsi. A solenoid coil wound on a slotted titanium frame sits inside the metallic sample holder and serves as an antenna to transmit RF pulses and receive NMR signals. The metal sample holder is sandwiched between a pair of gradient coils which provide a linear field gradient for pulsed field gradient diffusion measurements. The assembly sits in the bore of a low-gradient permanent magnet. The system can operate over a wide frequency range without the need for tuning the antenna to the Larmor frequency. The SNR measured on a water sample at room temperature is more than 15 times greater than that of the commercial low-field system in our laboratory. Thus, the new system provides for data acquisition more than 200 times faster than was previously possible. Laboratory NMR measurements of relaxations times and diffusion coefficients performed at pressures up to 25 Kpsi and at temperatures up to 175 °C with crude oils enlivened with dissolved hydrocarbon gases (referred to as “live oils”) are shown. This is the first time low-field NMR measurements have been performed at such high temperatures and pressures on live crude oil samples. We discuss the details of the apparatus design, tuning, calibration, and operation. NMR data acquired at multiple temperatures and pressures on a live oil sample are discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Structure and magnetic properties of low-temperature phase Mn-Bi nanosheets with ultra-high coercivity and significant anisotropy

The microstructure, crystal structure, and magnetic properties of low-temperature phase (LTP) Mn-Bi nanosheets, prepared by surfactant assistant high-energy ball milling (SA-HEBM) with oleylamine and oleic acid as the surfactant, were examined with scanning electron microscopy, X-ray diffraction, and vibrating sample magnetometer, respectively. Effect of ball-milling time on the coercivity of LTP Mn-Bi nanosheets was systematically investigated. Results show that the high energy ball milling time from tens of minutes to several hours results in the coercivity increase of Mn-Bi powders and peak values of 14.3 kOe around 10 h. LTP Mn-Bi nanosheets are characterized by an average thickness of tens of nanometers, an average diameter of ∼1.5 μm, and possess a relatively large aspect ratio, an ultra-high room temperature coercivity of 22.3 kOe, a significant geometrical and magnetic anisotropy, and a strong (00l) crystal texture. Magnetization and demagnetization behaviors reveal that wall pinning is the dominant coercivity mechanism in these LTP Mn-Bi nanosheets. The ultrafine grain refinement introduced by the SA-HEBM process contribute to the ultra-high coercivity of LTP Mn-Bi nanosheets and a large number of defects put a powerful pinning effect on the magnetic domain movement, simultaneously. Further magnetic measurement at 437 K shows that a high coercivity of 17.8 kOe and a strong positive temperature coefficient of coercivity existed in the bonded permanent magnet made by LTP Mn-Bi nanosheets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Calculation of ultrasonic fields radiated in a ferromagnetic medium by an EMAT of arbitrary bias field driven by a current of arbitrary intensity

ElectroMagnetic Acoustic Transducers (EMATs) are contactless transducers generating ultrasonic waves in conductive media, notably shear horizontal and torsional waves (in plates and pipes, respectively), possibly in hostile environments. In a ferromagnetic part, the elastic strain and the magnetic field couple through magnetostriction phenomena, so that a magnetostriction and magnetization forces add up to the Lorentz force created in any conductive medium. Here, a model is proposed to predict these forces for an arbitrary bias field due to the EMAT permanent magnet and whatever the current intensity in its electric circuit, whereas the usual assumption of high bias field and low intensity current leads to important model simplifications. To handle the nonlinear behavior of all the three forces when the usual assumption cannot be made, forces are expressed in the time domain. In particular, magnetostriction force generates waves at several harmonic frequencies of the driving current frequency. Forces are then transformed into equivalent surface stresses readily usable as source terms in existing models of ultrasonic radiation, under the assumption that ultrasonic wavelengths are much longer than force penetration depths, (which is generally true in NDT applications of EMATs). Force spectra computed in various EMAT configurations are compared for illustration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Microstructural and magnetic property evolution with different heat-treatment conditions in an alnico alloy

Further property enhancement of alnico, an attractive near-term, non-rare-earth permanent magnet alloy system, primarily composed of Al, Ni, Co, and Fe, relies on improved morphology control and size refinement of its complex spinodally decomposed nanostructure that forms during heat-treatment. Using a combination of transmission electron microscopy and atom probe tomography techniques, this study evaluates the magnetic properties and microstructures of an isotropic 32.4Fe-38.1Co-12.9Ni-7.3Al-6.4Ti-3.0Cu (wt.%) alloy in terms of processing parameters such as annealing temperature, annealing time, application of an external magnetic field, as well as low-temperature “draw” annealing. Optimal spinodal morphology and spacing is formed within a narrow temperature and time range (~840 °C and 10 min) during thermal-magnetic annealing (MA). The ideal morphology is a mosaic structure consisting of periodically arrayed ~40 nm diameter (Fe-Co)-rich rods (α 1 phase) embedded in an (Al-Ni)-rich (α 2 phase) matrix. A Cu-enriched phase with a size of ~3–5 nm is located at the corners of two adjacent {110} facets of the α 1 phase. The MA process significantly increased remanence (B r ) (~40–70%) of the alloy due to biased elongation of the α 1 phase along the <100> crystallographic direction, which is closest in orientation to the applied magnetic field. As a result, the optimum magnetic properties of the alloy with an intrinsic coercivity (H cj ) of 1845 Oe and a maximum energy product (BH max ) of 5.9 MGOe were attributed to the uniformity of the mosaic structure.

36 MATERIALS SCIENCE↗
DOE OSTI2016

One dimensional spatial resolution optimization on a hybrid low field MRI-gamma detector

Hybrid systems like Positron Emission Tomography/Magnetic Resonance Imaging (PET/MRI) and MRI/gamma camera, offer advantages combining the resolution and contrast capability of MRI with the better contrast and functional information of nuclear medicine techniques. However, the radiation detectors are expensive and need an electronic set-up, which can interfere with the MRI acquisition process or viceversa. In order to improve these drawbacks, in this work it is presented the design of a low field NMR system made up of permanent magnets compatible with a gamma radiation detector based on gel dosimetry. The design is performed using the software FEMM for estimation of the magnetic field, and GEANT4 for the physical process involved in radiation detection and effect of magnetic field. The homogeneity in magnetic field is achieved with an array of NbFeB magnets in a linear configuration with a separation between the magnets, minimizing the effect of Compton back scattering compared with a no-spacing linear configuration. The final magnetic field in the homogeneous zone is ca. 100 mT. In this hybrid proposal, although the gel detector do not have spatial resolution per se, it is possible to obtain a dose profile (1D image) as a function of the position by using a collimator array. As a result, the gamma detector system described allows a complete integrated radiation detector within the low field NMR (lfNMR) system. Finally we present the better configuration for the hybrid system considering the collimator parameters such as height, thickness and distance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2016

Ab initio calculations of magnetic properties of the interstitially doped YFe{sub 11}Mo compound

The recent increase in the number of studies of RFe{sub 11–x}M{sub x} compounds is related to their promising application as permanent magnets. However, the insufficiently high value of the Curie temperature T{sub C} of these compounds is a barrier to their widespread use. The increase in the Curie temperature of these compounds is achieved by doping with the light nonmetallic atoms such as hydrogen, nitrogen, and carbon. In this paper, it is shown numerically that this doping leads to drastic changes of the electronic band dispersions in a wide energy region around the Fermi level. This in turn changes values of the magnetic moments of ions and Heisenberg exchange interaction parameters. The values of ab initio calculated magnetic moments and direct exchange interaction parameters make it possible to calculate the Curie temperatures for both parent and nitrogen-doped compounds within the mean-field approach to the Heisenberg model in the sample of YFe{sub 11}Mo, a typical representative of the R(Fe,M){sub 12}L class. Theoretical values of T{sub C} obtained for YFe{sub 11}Mo and YFe{sub 11}MoN (514 and 723 K respectively) are consistent with experimental ones (472 and 664 K) with an accuracy of 10%. Also, the calculated increase in T{sub C} upon nitrogenization (about 200 K) is in good agreement with the experimental data.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Sm{sub 2}Fe{sub 17}N{sub x} nanoflakes prepared by surfactant assisted cryomilling

Hard magnetic Sm{sub 2}Fe{sub 17}N{sub x} nanoflakes were prepared by surfactant assisted ball milling (SABM) at low temperature using liquid nitrogen cooling (surfactant assisted cryomilling). 2-methyl pentane was used as a milling medium and oleylamine as a surfactant. The morphology, structure, and magnetic properties of Sm{sub 2}Fe{sub 17}N{sub x} were investigated using scanning electron microscopy, X-ray diffraction, and vibrating sample magnetometer, respectively. By comparing Sm{sub 2}Fe{sub 17}N{sub x} nanoflakes produced by SABM at low temperature and at room temperature, we found that the former has many interesting features: more homogeneous morphology, smaller size, especially markedly increased remanent magnetization (M{sub r}), saturation magnetization (M{sub s}), and remanent magnetization ratio (M{sub r}/M{sub s}). These Sm{sub 2}Fe{sub 17}N{sub x} nanoflakes have great potential to be used for preparing high performance bonded permanent magnets.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Effect of vanadium on phase composition and hard magnetic properties of as-solidified and heat-treated Sm–Fe–(Ti,V) alloys

Although the intrinsic magnetic properties of Ti-stabilized Sm(Fe,Co,Ti) 12 compounds exhibit potential of excellent rare-earth-lean permanent magnets, it has been much easier to realize large coercivities with the isostructural compounds stabilized by either V or by certain combinations of Ti and V. To elucidate the influence of V on the microstructure and magnetic properties, a series of Sm 8.1 Fe 78.4 (Ti 1-x V x ) 13.5 alloys was studied after arc-melting and annealing at 850–1000 °C. The alloys were found to fall into three groups. For x ≤ 0.2, solidification generates mostly the Sm(Fe,Ti,V) 12 phase, but annealing converts at least part of it into the non-magnetic Sm(Fe,Ti,V) 11 and the magnetically soft Sm 2 (Fe,Ti,V) 17 phases. For 0.2 < x < 0.6, the alloys solidify into a near-equilibrium mixture of the Sm(Fe,Ti,V) 12 , TiFe 2 and Sm-rich phases. For x ≥ 0.6, solidification generates large fractions of α-Fe solid solution and Sm-rich phases; an annealing step is necessary to complete the formation of Sm(Fe,Ti,V) 12 phase. Also, for x ≥ 0.6 the temperature below which the Sm(Fe,Ti,V) 12 phase is stable decreases with x, as does the fraction of this phase formed during solidification. Here, the differences between these three groups of alloys suggest different strategies for developing hard magnetic properties, with the likelihood of a success increasing with increasing x. For x ≥ 0.6, heat treatment alone is demonstrated to generate a microstructure of micron and submicron Sm(Fe,Ti 1-x V x ) 12 crystallites separated by a Sm-rich phase and exhibiting a coercivity with values up to 3.5 and 5.7 kOe for x = 0.8 and 1.0, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Novel motor design for rotating anode x-ray tubes operating in the fringe field of a magnetic resonance imaging system

Purpose: Using hybrid x-ray/MR (XMR) systems for image guidance during interventional procedures could enhance the diagnosis and treatment of neurologic, oncologic, cardiovascular, and other disorders. The authors propose a close proximity hybrid system design in which a C-arm fluoroscopy unit is placed immediately adjacent to the solenoid magnet of a MR system with a minimum distance of 1.2 m between the x-ray and MR imaging fields of view. Existing rotating anode x-ray tube designs fail within MR fringe field environments because the magnetic fields alter the electron trajectories in the x-ray tube and act as a brake on the induction motor, reducing the rotation speed of the anode. In this study the authors propose a novel motor design that avoids the anode rotation speed reduction. Methods: The proposed design replaces the permanent magnet stator found in brushed dc motors with the radial component of the MR fringe field. The x-ray tube is oriented such that the radial component of the MR fringe field is orthogonal to the cathode-anode axis. Using a feedback position sensor and the support bearings as electrical slip rings, the authors use electrical commutation to eliminate the need for mechanical brushes and commutators. A vacuum compatible prototype of the proposed motor design was assembled, and its performance was evaluated at various operating conditions. The prototype consisted of a 3.1 in. diameter anode rated at 300 kHU with a ceramic rotor that was 5.6 in. in length and had a 2.9 in. diameter. The material chosen for all ceramic components was MACOR, a machineable glass ceramic developed by Corning Inc. The approximate weight of the entire assembly was 1750 g. The maximum rotation speed, angular acceleration, and acceleration time of the motor design were investigated, as well as the dependence of these parameters on rotor angular offset, magnetic field strength, and field orientation. The resonance properties of the authors' assembly were also evaluated to determine its stability during acceleration, and a pulse width modulation algorithm was implemented to control the rotation speed of the motor. Results: At a magnetic flux density of 41 mT orthogonal to the axis of rotation (on the lower end of the expected flux density in the MR suite) the maximum speed of the motor was found to be 5150 revolutions per minute (rpm). The acceleration time necessary to reach 3000 rpm was found to be approximately 10 s at 59 mT. The resonance frequency of the assembly with the anode attached was 1310 rpm (21.8 Hz) which is far below the desired operating speeds. Pulse width modulation provides an effective method to control the speed of the motor with a resolution of 100 rpm. Conclusions: The proposed design can serve as a direct replacement to the conventional induction motor used in rotating anode x-ray tubes. It does not suffer from a reduced rotation speed when operating in a MR environment. The presence of chromic steel bearings in the prototype prevented testing at the higher field strengths, and future iterations of the design could eliminate this shortcoming. The prototype assembly demonstrates proof of concept of the authors' design and overcomes one of the major obstacles for a MR compatible rotating anode x-ray tube.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Ultra High-Temperature Magnetic Bearing System for s-CO 2 Turbines/Expanders. Phase II Final Report

The goal of this project is to design and construct of a prototype of ultra-high temperature permanent magnet (UHT–PM), which provides the force to pull the spinning shaft towards the target position in the magnetic bearing (MB) clearance circle. This project will develop a PM biased MB system, that is actively cooled to the 550°C maximum operating temperature limit of PMs. The MB test environment will include 700°C, 40krpm and 4,000 psi requirements to advance the supercritical carbon dioxide (sCO 2 ) and other types of Brayton power cycle systems. The proposed novel MBs combine PMs for supplying the bias field and electromagnets for supplying the control field, both in UHT conditions. The choice of material is the UHT Sm-Co PMs (US patent 6,451,132) due to their significantly better thermal stability. The 6-pole homopolar design permits uninterrupted force delivery via a redundant control capability (US patent 7,429,811) even if 3 poles were to fail. The Phase I efforts was to focus on development and demonstration of component technologies and detailed design of full scale components and a demonstrator test rig for use in Phase II. UHT–PMs were produced and used in the MB actuator. The operating environment of the EEC-T550 Sm-Co magnet material could be extended by implementing active cooling. Electromagnetic coils imbedded in the MB provide forces to stabilize the shaft position at the target via sensing and control stages. Shaft position sensors enable to identify the present position of the spinning shaft relative to its desired target position in the MB clearance circle (air gap). Auxiliary bearings will be installed to provide a backup support system in the event that power to the MB fails or there is a fault in a device providing current to the MB coils. For control, reliability and safety reasons the sensors and auxiliary bearings are typically located as close as possible to the MBs, which exposes them to the same environmental conditions. Development of only the actuator for the UHT environment is an inadequate approach to complete integration of the MB system in the turbine/expander. Therefore the UHT sensor and auxiliary bearing were designed and developed along with the actively cooled, UHT-PM actuator development. Although shaft position sensors are commercially available (Kaman) they may cost up to $10k per channel, and a full 5 axis magnetic suspension is best implemented with up to 20 sensors. Once successfully completed, this project will significantly extend the operating environment capability for turbomachinery applications such as nuclear power, concentrated solar thermal, fossil fuel, geothermal, and shipboard propulsion. The further advancement of UHT-PM-MB will also strengthen the US position in PM technology, which is presently heavily dominated by China. The UHT Sm-Co magnet material that will be utilized in the proposed work has been developed exclusively by the project proposer. Many actuators, motors, generators and other MB applications will greatly benefit from the proposed work.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

On dysprosium utilisation in multi-main-phase Nd–Dy–Fe–B magnets with core–shell microstructures

The development of high-performance Nd–Dy–Fe–B magnets that minimise the consumption of the scarce rare earth (RE) element Dy remains a major global scientific and technological quest. Here, we designed an alloy microstructure comprising of a uniform Dy-lean core–Dy-rich shell in a series of multi-main-phase (MMP) Nd–Dy–Fe–B magnets. The resulting MMP Dy1 and Dy3 magnets with an overall Dy level of 1 and 3 wt.% possessed values of 0.48 and 0.29 T/wt.% of coercivity increment per unit weight percentage of the Dy addition, respectively. Most importantly, the resulting MMP Dy3 magnet exhibited a high coercivity (2.38 T), an excellent thermal stability of the coercivity (|β| = 0.531%/°C), a high squareness factor (> 95%), all with little diminishment in the remanent magnetisation (1.35 T) and maximum energy product (43.6 MGOe). These properties are superior to the currently available sintered Nd–Dy–Fe–B magnets which utilise higher levels of Dy of 5 wt.%. Via magnetic and multi-scale microstructural characterisation experiments and micromagnetic simulations, the formation of the Dy-lean core–Dy-rich shell microstructure is rationalised via solid-state-diffusion and solution reprecipitation during liquid-phase sintering. The Dy-lean core–Dy-rich shell microstructure and the non-ferromagnetic low-Fe RE-rich grain boundary phase led to the synergistic magnetic performance. This is significant in the context of the MMP Nd–Dy–Fe–B magnets being applied to large-scale production. The present work establishes a pathway for the more sustainable utilisation of Dy in permanent magnets via formation of a uniform core–shell microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Tetragonal structure and uniaxial magnetic anisotropy in the arc-melted (Ce,Zr) 2 (Fe,M) 17 (M = Mo, W, Co) alloys

The tetragonal ThMn 12 -type structure is stabilized in (Ce 1-x Zr x ) 2 T 16 M (x = 0.2 – 0.3; T = Fe or Fe/Co, M = Mo or W) arc-melted alloys. Approximately 5 at% of Mo or W admixture is sufficient to transform the hexagonal Th 2 Ni 17 -type structure of (Ce 1-x Zr x ) 2 Fe 17 into the tetragonal ThMn 12 -type structure of nearly single-phase (Ce 1-x Zr x ) 2 Fe 16 M and/or (Ce 1-x Zr x ) 2 Fe 15 CoM bulk alloys. X-ray Rietveld refinements reveal that Zr and Mo (W) substitute different sites in the tetragonal crystal structure. Zirconium preferentially replaces Ce, whereas Mo (W) substitutes Fe. At room temperature, the tetragonal phases exhibit strong ferromagnetism and a uniaxial magneto-crystalline anisotropy with anisotropy fields of 15 – 17 kOe. These materials possess room-temperature saturation magnetizations of 95 – 105 emu/g and Curie temperature of 420 – 505 K. At some concentrations, concurrent Zr and Mo (W) site occupancy facilitates 1:12 structure formation in bulk alloys with minimal presence of non-magnetic element in the Fe sublattice, thus securing the highest known magnetic moment per Fe atom (∼ 1.37 µ B ) in this type of materials. The intrinsic magnetic characteristics, as well as the absence of critical rare earths (RE), make these compounds interesting for development as low-cost permanent magnets. In conclusion, small Co additions improve the Curie temperature, especially if combined with W.

36 MATERIALS SCIENCE↗