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DOE OSTI2025

Distinct effect of Kondo physics on crystal field splitting in electron and spin spectroscopies

Magnetic anisotropy is a key feature of rare earth materials from permanent magnets to heavy fermions. Here we explore the complex interplay of Kondo physics and anisotropy, and their effect on different experimental probes of magnetic anisotropy in a minimal 𝐽=3/2 Anderson impurity model using the numerical renormalization group. While anisotropy suppresses Kondo screening, virtual valence fluctuations enhance the anisotropy. We find distinct renormalization of the magnetic anisotropy measured via dynamical spin response (inelastic neutron scattering) versus electronic excitations in the impurity spectral function (resonant inelastic x-ray and scanning tunneling spectroscopy). The two measurement types have different responses and dependencies on the temperature and Kondo scales.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2026

Aluminum bonded SmCo5 magnets with enhanced mechanical strength

Despite their versatility and easy manufacturability, polymer-bonded magnets find limited application due to their limited mechanical properties and temperature resistance. In this study, we developed mechanically robust, aluminum-bonded SmCo5 magnets by utilizing a low-temperature, shear-assisted friction consolidation technique. Bonded magnets with varying magnetic phase content were fabricated at processing temperature of 500°C, and their microstructures, magnetic, mechanical, and electrical properties were systematically investigated. The resulting bonded-magnets showed effective consolidation with nanocrystalline microstructures. Magnetic properties were found to be tunable through variations in binder phase content, with coercivity reaching values up to 15.3 kOe (1217.5 kA/m) and maximum magnetic energy product up to 3.6 MGOe (28.7 kJ/m3), which are comparable to other bonded magnets. Electrical resistivities were lower than the polymer-bonded magnets, but comparable to the sintered ones. We observed an average flexural strength of 223 MPa for 60 vol.% SmCo5/Al sample, which is nearly two times higher than the reported values for sintered and bonded Sm-Co magnets. Our research demonstrated an effective approach to fabricate metal-bonded permanent magnets with superior magnetic and mechanical properties potentially applicable for high temperature applications.

Poudel Chhetri, Tej Bahadur↗

DOE OSTI2026

High-gradient magnetic filtration of UO 2 colloids from aqueous suspensions

Environmental samples often contain innocuous components that make trace actinide analysis difficult and expensive. Therefore, it is expedient to separate these materials from actinide particles. One characteristic of many actinides is that they are paramagnetic. High-gradient magnetic filtration (HGMF) is a non-destructive technique that selectively captures magnetic constituents from a matrix containing non-magnetic species. Here, in this work, a novel HGMF device made of a permanent magnet array was used to effectively separate UO 2 particles from undesirable soil species. Up to 88% of the UO 2 particles present in suspensions were effectively captured by HGMF, resulting in their enrichment and a substantial reduction in the concentrations of other constituents.

Actinide separations↗

DOE OSTI2024

A compact and portable gamma-ray spectrometer (GRASP) for inertial confinement fusion and basic science experiments

A compact and portable gamma-ray spectrometer has been designed to diagnose different components of the inertial confinement fusion-relevant γ-ray spectrum with energies between ∼3.7–17.9 MeV. The system is designed to be as compact as possible for convenient transportation and fielding in diagnostic ports on the OMEGA laser, the National Ignition Facility, and other photon-source facilities. The system consists of a conversion foil for Compton scattering in front of four magnetic spectrometer “arms,” each covering a different energy range and constructed out of cylindrical permanent magnet Halbach arrays. Monte Carlo simulations have been used to optimize and assess the performance of the conversion foil, and COSY INFINITY ion-optical simulations have been used to optimize the spectrometer magnets. The performance of the design is assessed for a simulated direct-drive γ-ray spectrum. Spanning its total γ-ray energy bandwidth and using a 1.7 mm thick boron conversion foil, the system’s total energy resolution and efficiency are ∼15.8%–4.5% and 5.4 × 10−7–3.7 × 10−7e−/γ, respectively, with room for improvement. Spectral γ-ray measurements will provide guidance to the inertial confinement fusion program toward achieving high-energy gain relevant to inertial fusion energy and enable new measurement capabilities for basic discovery science.

Instruments & Instrumentation↗

DOE OSTI2025

Enhancing stability, magnetic anisotropy, and coercivity of manganese aluminum: Machine learning, ab initio , and micromagnetic modeling

The binary manganese aluminum (MnAl) alloy with L⁢1 0 crystal structure is a promising rare earth (RE) element-free permanent magnetic material because of its exceptional magnetic properties. However, experimentally synthesizing it in a stable bulk form is extremely challenging. Here, in this study, an alternative method of stabilizing the material, a pathway for experimental synthesis and validation, is proposed and theoretically verified. This is done by partially substituting Mn and Al sites with Fe and Ni and identifying its enhanced phase stability, saturation magnetization density, magnetic anisotropy, and coercivity from density functional theory (DFT), machine learning (ML) crystal graph convolution neural network (CGCNN), and micro-magnetic modeling. When considering a fixed 50% Ni, the magnetic anisotropy increases with the increasing Fe content but decreases the formation energy. The calculated formation energies, elastic constants, and phonon frequencies demonstrate that the binary and quaternary compositions are stable. Most importantly, in 50% Fe and Ni-substituted-equiatomic phase, magnetic anisotropy constants and saturation magnetization density increase by 56% and 23% as compared to the MnAl. Further, the coercivity of the equiatomic phase predicted with micro-magnetic modeling is higher by 17% than the parent compound.

Bhandari, Churna [Ames National Laboratory, and Io↗

DOE OSTI2024

Intrinsic and hard magnetic properties of (Sm 1-x R x )-Fe-Co-V alloys (R = Gd, Zr, and Y)

SmFe 12 -based compounds with the ThMn 12 -type structure have a great potential as future rare-earth-lean permanent magnets. However, their reliance on stabilizing non-magnetic elements has impeded practical applications. Therefore, elements such as Gd, Y, and Zr have gained popularity as candidates to minimize the need for stabilizing elements by reducing the formation energy of the ThMn 12 (1:12) phase. Here, this study examines the effect of Gd, Y, and Zr on the intrinsic and hard magnetic properties in (Sm 1-x R x ) 1.2 Fe 8.4 Co 2.1 V 1.5 (or with nominal composition of (Sm 1-x R x ) 9.1 Fe 63.6 Co 15.9 V 11.4 ) with a single 1:12 phase for 0 ≤ x ≤ 0.3. Notably, samples substituted with Gd exhibit an enhanced temperature dependence of the magnetic properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Experiments in 3D Printing Electric Motors

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.

3D printed motor↗

DOE OSTI2026

Multi-GeV FFA beam transport test at CEBAF

Jefferson National Lab plans an upgrade project to reach 22 GeV high polarization electron beam by using Fixed Field Alternating-gradient (FFA) magnets. The utilization of the FFA magnets for 10-22 GeV beam energy range is unexampled, therefore those magnets need an experimental validation before their full installation to form an arc in the Continuous Electron Beam Accelerator Facility (CEBAF). For this reason, JLAB is also considering the design of an FFA magnet test bench, i.e. a half or full FFA cell, that would be deployed in the current CEBAF in order to serve as the highest energy demonstration for the FFA field uniformity, permanent magnet resiliency with the beam as well as enabling beam optics measurements with the 5-11 GeV range highly polarized beams which closely resembles the full energy range of the 22 GeV upgrade. In this report, we present the status of the planned beamline for the FFA beam transport test at CEBAF.

Accelerator Physics↗

DOE OSTI2026

Searching for ternary magnetic Zr–Fe–B compounds through deep machine learning

We use deep machine learning (ML) combined with first-principles calculations to search for energetically favorable ternary magnetic zirconium–iron borides. We show that an iterative ML approach enables efficient screening of vast structural libraries, effectively selecting promising candidates for subsequent first-principles investigations. Twenty-two new Fe-rich ternary compounds with formation energies within 60 meV atom −1 above the known ternary convex hull and with magnetic polarization larger than 0.6 T are identified, among which ten structures exhibit significant uniaxial anisotropy with magnetocrystalline anisotropy constant K 1 ⩾ 0.8 MJ m −3 , including a Zr 2 Fe 14 B phase. Such an ML-guided approach dramatically accelerates the discovery of rare-earth-free permanent magnetic materials.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Electromagnetic Modeling of Lattice Structures in Additively Manufactured Electric Machines

Recent advancements in metal additive manufacturing (AM) show great potential to revolutionize the design and manufacturing of electromagnetic components used in the field of electrical engineering. Lattice structures directly printed by AM processes typically offer better structural performance with reduced weight, such as high stiffness, surface area, elongation, energy absorption, and porosity, than the solid counterpart. This paper aims to study the electromagnetic modeling of lattice structures used in additively manufactured magnetic cores or windings for electric machines. Three dimensional (3D) electromagnetic finite element (FE) analysis with high performance computing (HPC) shows the highest fidelity in predicting the electromagnetic performance of designs with lattice structures by preserving complex geometry details. FE-based homogenization methods have also been explored to potentially speed up concept design. A case study based on an additively manufactured axial-flux permanent magnet machine with a Hilbert pattern stator validates the discussed electromagnetic modeling approaches.

Chung, Shi-Uk [ANSYS, Inc.]↗

DOE OSTI2025

Chloride Molten Salt Electrolysis Enables Integrated and Energy-Efficient Process for NdFeB Magnet Fabrication

Rare-earth elements (REEs) have been identified by NATO, the USDOE, and USGS as critical materials, i.e., materials which have significant demand yet pose supply-chain risks. Many of the existing processes for separations, metallization, and final parts production used across the REE supply chain involve energy intensive steps. For example, neodymium (Nd or NdPr) is produced using oxyfluoride electrolysis of Nd 2 O 3 , which requires hydrofluoric acid to produce a key electrolyte component (NdF 3 ) and generates undesired perfluorocarbon (PFC) gases. Such challenges make securing a resilient supply chain for NdFeB permanent magnets in countries like the United States prohibitively difficult. Here, we propose a chloride-based MSE process that circumvents these challenges, delivering high-purity NdPr from a (NdPr)Cl 3 feed from upstream REE separations. This eliminates environmentally-damaging steps of oxalate or carbonate precipitation and calcination, and enables superior production rates due to greater solubility of (NdPr)Cl 3 in chloride melts compared to Nd 2 O 3 . We show that CMSE generates high-purity NdPr (99.4 wt.%) while being energy-efficient (~ 6 kWh/kg-Nd). NdPr from CMSE was used to fabricate a NdFeB magnet with an excellent maximum energy product (> 40 MGOe), comparable to commercially available NdFeB magnets. This establishes CMSE as a leading approach for integrated, energy-efficient NdFeB magnet production.

Materials science↗

DOE OSTI2026

FFA BEAM TRANSPORT DEMONSTRATION DEVELOPMENT FOR THE CEBAF 22 GeV UPGRADE

Jefferson Lab is planning an upgrade of the Continuous Electron Beam Accelerator Facility (CEBAF) to deliver highly polarized electron beams up to 22 GeV using Fixed- Field Alternating-gradient (FFA) magnets. As the application of FFA technology in the 10–22 GeV energy range is unprecedented, experimental validation is required prior to full-scale implementation. To support this effort, a dedicated FFA test insert is proposed within the existing CEBAF infrastructure, with candidate locations in the Beam Switchyard (BSY) dump line or the Hall C beamline. The testbed will consist of a half or full FFA cell using combined-function permanent magnets and will enable systematic studies of beam transport, field quality, alignment, and magnet performance under realistic conditions. Operation with polarized beams in the 5–11 GeV range will closely replicate the energy scaling of the full upgrade. This paper presents the current design status and layout options for the proposed FFA beam transport test line.

Ogur, S. [Thomas Jefferson National Accelerator Fa↗

DOE OSTI2025

An experimental platform for investigating astrophysically relevant magnetized plasma jets on the COBRA facility

A new platform has been developed for the 1-MA COBRA generator to investigate the physical processes affecting the formation, collimation, and stability of high-speed outflows in magnetically driven laboratory plasma jets. Such experiments serve as diagnostically accessible surrogates for astrophysical jets under the assumption that the underlying dynamics are scale invariant. In contrast to previous current driven high energy density laboratory jet experiments that use radial/conical wire arrays or foils, the platform described here uses azimuthally symmetric gas-puff injection. This avoids the ablation phase from a solid target, allowing the jets to develop earlier and be driven longer without depleting their mass source and disrupting. A permanent magnet provides an initial poloidal magnetic field, which links the two concentric electrodes and mimics the boundary conditions of a star-accretion disk system. Extended magnetohydrodynamic effects can be assessed using a polarity convolute, which allows for reversal of the electrode bias. The resulting plasma jets exhibit remarkable stability, persisting for hundreds of nanoseconds and achieving aspect ratios ≳30:1.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Selective Recovery of Critical Minerals from Simulated Electronic Wastes Via Reaction‐Diffusion Coupling

Abstract Atom‐ and energy‐efficient chemical separations are urgently needed to meet the surging demand for critical materials that has strained supply chains and threatened environmental damage. In this study, we used reaction‐diffusion coupling to separate iron, neodymium, and dysprosium ions from model feedstocks of permanent magnets, which are typically found in electronic wastes. Feedstock solutions were placed in contact with a hydrogel loaded with potassium hydroxide and/or dibutyl phosphate, resulting in complex precipitation patterns as the various metal ions diffused into the reaction medium. Specifically, we observed the precipitation of up to 40 mM of iron from the feedstock, followed by the enrichment of 73 % dysprosium, and the extraction of >95 % neodymium product at a further distance from the solution‐gel interface. We designed a series of experiments and simulations to determine the relevant ion diffusivities, D Nd =5.4×10 −10 and D Dy =5.1×10 −10 m 2 /s, and precipitation rates, k Nd =1.0×10 −5 and k Dy =5.0×10 −3 m 9 mol −3 s −1 , which enabled a numerical model to be established for predicting the distribution of products in the reaction medium. Our proof‐of‐concept study validates reaction‐diffusion coupling as an effective and versatile approach for critical materials separations, without relying on ligands, membranes, resins, or other specialty chemicals.

Wang, Qingpu [Physical and Computational Sciences ↗

DOE OSTI2027

Conceptual design of highly-constrained splitters for the FFA@CEBAF energy upgrade study

The Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab is investigating a significant energy upgrade utilizing Fixed-Field Alternating-gradient (FFA) recirculating arcs. This upgrade requires the design of complex horizontal beam splitters to manage up to six concurrent beam passes. This paper presents the conceptual design of these splitters, which are subject to severe physical constraints imposed by the existing accelerator tunnel and multifaceted beam dynamics requirements for matching into the permanent-magnet FFA arcs. The design methodology, centered on multi-pass simulations in the Bmad toolkit, is detailed from the initial geometric layout through the advanced optics matching. Key results include a robust geometric arrangement that fits within the spatial boundaries and the development of multiple, flexible optics matching solutions. Furthermore, the design integrates a viable scheme for extracting high-energy beams for the experimental halls, a critical operational requirement. This work establishes a comprehensive and viable conceptual design, forming a baseline for future engineering and performance optimization studies.

Bodenstein, R.M. [Thomas Jefferson National Accele↗

DOE OSTI2025

Search for Stable and Low-Energy Ce–Co–Cu Ternary Compounds Using Machine Learning

Cerium-based intermetallics have garnered significant research attention as potential new permanent magnets. In this study, we explore the compositional and structural landscape of Ce−Co−Cu ternary compounds using a machine learning (ML)- guided framework integrated with first-principles calculations. We employ a crystal graph convolutional neural network (CGCNN), which enables efficient screening for promising candidates, significantly accelerating the material discovery process. With this approach, we predict five stable compounds, Ce 3 Co 3 Cu, CeCoCu 2 , Ce 12 Co 7 Cu, Ce 11 Co 9 Cu, and Ce 10 Co 11 Cu 4 , with formation energies below the convex hull, along with hundreds of low-energy (possibly metastable) Ce−Co−Cu ternary compounds. Firstprinciples calculations reveal that several structures are both energetically and dynamically stable. Notably, two Co-rich low-energy compounds, Ce 4 Co 33 Cu and Ce 4 Co 31 Cu 3 , are predicted to have high magnetizations.

Chemical structure↗

DOE OSTI2026

Fluorescence Signatures of Rare Earth Metals during Precipitation in Various Conditions

Fluorescence spectroscopy is a widely used sensor methodology that analyzes light emitted from a compound or element as it decays from an excited state. This technique is very sensitive and selective, which is ideal to characterize analytes at lower limits of detection. Key example targets of significant industry and research interest include rare earth elements (REEs) such as dysprosium (Dy) and europium (Eu). These are widely used in advanced technologies including semiconductors, electric vehicle motors, lasers, and permanent magnets. Identifying new sources and responsible reutilization of REEs is essential, and new approaches to extract and recycle REEs could be notably enhanced through the integration of on-line sensors. The sensors can support faster process design, informed scale-up, and cost-effective deployment. This study covers the initial exploration of applying fluorescence-based on-line monitoring to REEs within a precipitation process. This study demonstrates the successful scale-up of a fluorescence -based sensing approach, from stationary cuvettes and small-volume microfluidic devices to continuous flow systems operating at the bench scale (10-25mL). This work also provides initial insight into the challenges of signal’s effects and utility within a turbid environment. Using a modular design for monitoring flowing solutions in a flow tube, fluorescence can be characterized for a variety of analytical targets. In this study, detection performance parameters between the cuvette and flow tube system were compared. Additionally, the response of Dy during precipitation by sodium bicarbonate in the two measurement designs was explored. This letter represents a starting point to bridge the gap between traditional fluorescence sensor measurements in a cuvette to future developments that explore the ability to integrate fluorescence sensors into extraction and separation processes at industrially relevant scales.

fluorescence↗

DOE OSTI2025

Rare earth metals production using alternative feedstock that eliminates HF

This work reports the successful production of rare earth (RE) metal using Na-RE-F. Presently, RE metals are primarily produced using RE-fluoride due to its higher air and moisture stability compared to RE-chloride. However, its preparation requires the use of corrosive and hazardous chemicals, such as hydrofluoric acid (HF) or ammonium bifluoride (NH 4 HF 2 ). The present study demonstrates that Na-RE-F is an alternative salt to the typically used RE-fluoride. The Na-RE-F for this work is produced via a scalable hydrometallurgical approach using three different RE salts as feedstock, including acetate, nitrate, and chloride. HF is neither used nor generated during the salt preparation process. Furthermore, the Na-RE-F powder dries in air (without dry HF), and only water evolves during the drying process. Analyses of the Na-RE-F show that NaF liberates as a flux during the heating process, which lowers the salt reduction temperature to <900 °C, thus minimizing or eliminating the need for additional flux. Calciothermic reduction of the Na-RE-F salt is successfully employed to obtain RE metal. This work represents a safer, greener, and more widely deployable approach for producing the RE metals needed for permanent magnets which support the transition to a cleaner society through the decarbonization of the transportation industry.

36 MATERIALS SCIENCE↗