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Progress in Magnetic Gearing for Aeronautics and Space Applications

Magnetic gears harness the magnetic force between non-contacting sets of permanent magnets. They achieve a gear ratio through the geometry and constrained motion of the magnets or the transformation of the magnetic fields by carefully shaped soft magnetic material. Their non-contact nature eliminates the need for gear lubrication and the wear mechanisms associated with mechanical contact. Magnetic gears have the potential to reduce the strong, tonal vibration and noise that is inherent to mechanical gears. Magnetic gears are also easily integrated into electric machines because they rely on the same physics and utilize the same materials and many of the same components. For these reasons and the invention of higher performing magnetic gear configurations over the past 20 years, magnetic gears have received growing attention for aerospace applications. This presentation summarizes the motivation for studying magnetic gears and the progress made in developing the technology to meet the demanding requirements of aerospace applications. The focus is on the development completed and ongoing at NASA, but SBIR projects in the field are summarized. The discussion focuses on the application of magnetic gears and magnetically-geared motors in electrified aircraft propulsion systems and actuation systems for space mechanisms. The NASA work includes the design, optimization, and testing of magnetic gears and magnetically-geared motors for electrified vertical takeoff and landing aircraft and the design and ambient environment testing of a magnetically-geared actuator for use in extremely cold and dusty space environments. The presentation concludes with thoughts on the technical barriers to adoption and potentially fruitful topics for future research.

Justin J. Scheidler↗

DOE OSTI2022

Superconducting Magnet System Concept with a Mechanical Energy Transfer in the Magnetic Field

There is an interest to design superconducting magnet systems working in a persistent current mode. These systems continuously generate magnetic field with disconnected power source working like permanent magnet devices. In this paper proposed a magnet system concept based on the direct mechanical energy transfer in the magnetic field. Short circuited superconducting coils do not have current leads and power source. To pump the mechanical energy in the superconducting coil used a magnetizer which magnetically coupled with the coil. The mechanical removing the magnetizer from the magnet induces a persistent current in the superconducting coil which generates the magnetic field. Iron dominated magnet system concept was investigated using OPERA3d code which confirmed a visibility of proposed approach.

43 PARTICLE ACCELERATORS↗

DOE OSTI2017

Record high magnetic ordering temperature in a lanthanide at extreme pressure

Today's best permanent magnet materials, SmCo 5 and Nd 2 Fe 14 B, could likely be made signi fi cantly more powerful were it not necessary to dilute the strong magnetism of the rare earth ions (Sm, Nd) with the 3 d transition elements (Fe, Co). Since the rare-earth metals order magnetically at relatively low temperatures T o <= 292 K, transition elements must be added to bring T o to temperatures well above ambient. Under pressure T o (P) for the neighboring lanthanides Gd, Tb, and Dy follows a notably nonmonotonic, but nearly identical, dependence to similar to 60 GPa. At higher pressures, however, Tb and Dy exhibit highly anomalous behavior, T o for Dy soaring to temperatures well above ambient. In conclusion, we suggest that this anomalously high magnetic ordering temperature is an heretofore unrecognized feature of the Kondo lattice state.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Chemical Synthesis of Magnetically Hard and Strong Rare Earth Metal Based Nanomagnets

We report here a general chemical approach to synthesize strongly ferromagnetic rare-earth metal (REM) based SmCo and SmFeN nanoparticles (NPs) with ultra-large coercivity. The synthesis started with the preparation of hexagonal CoO+Sm 2 O 3 (denoted as SmCo-O) multipods via decomposition of Sm(acac) 3 and Co(acac) 3 in oleylamine. These multipods were further reduced with Ca at 850 °C to form SmCo 5 NPs with sizes tunable from 50 to 200 nm. The 200 nm SmCo 5 NPs were dispersed in ethanol, and magnetically aligned in polyethylene glycol (PEG) matrix, yielding a PEG-SmCo 5 NP composite with the room temperature coercivity (H c ) of 49.2 kOe, the largest H c among all ferromagnetic NPs ever reported, and saturated magnetic moment (M s ) of 88.7 emu g -1 , the highest value reported for SmCo 5 NPs. The method was extended to synthesize other ferromagnetic NPs of Sm 2 Co 17 , and, for the first time, of Sm 2 Fe 17 N 3 NPs with H c over 15 kOe and M s reaching 127.9 emu g -1 . These REM based NPs are important magnetic building blocks for fabrication of high-performance permanent magnets, flexible magnets, and printable magnetic inks for energy and sensing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Aluminum/SmCo 5 composites for structural and magnetic applications

Metal-bonded magnetic composites (MBMCs) present a promising alternative to dense sintered magnets, particularly for intricate components. Compared to polymer-based bonded magnets, MBMCs have wider applicability in harsh environments. In this paper, we demonstrate a solid-state shear-based manufacturing technique to introduce localized magnetization into a paramagnetic aluminum matrix by embedding SmCo5 permanent magnet particles. Our magnetic composites display hard magnetic behavior with a coercivity of 13 kOe and a remanent magnetization of 4.32 emu/g. In addition to magnetization, we also report a 9% improvement in Young’s modulus. Despite the local temperature rise during processing, the magnetic phases didn’t decompose into unwanted phases, preserving the composite's hard magnetic properties. Creation of an interfacial metallurgical bond with the matrix ensured the suitability of the composites for structural applications. Our study investigates the mechanical, and functional properties of composites, paving the way for lightweight structural magnetic composites with a transformative potential in the aerospace, nuclear, and automotive applications. This work underscores the potential for further optimization and development to drive innovations in magnet and equipment design.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Magnetic properties of Co-Zr-B magnets produced by spark plasma sintering method

Magnets of Co-Zr-B, one of the permanent magnetic compounds without rare-earth elements, were successfully produced by the spark plasma sintering method. The resultant Co-Zr-B magnets had high densities of 92%–96% and consisted mainly of the Co{sub x}Zr (x ≈ 5) phase. The coercivity of the Co-Zr-B magnets was highly dependent on the consolidation temperature and the boron content. The highest maximum energy product of 6.0 MGOe, with a remanence of 6.4 kG and the coercivity of 4.0 kOe, was achieved by the Co{sub 80}Zr{sub 18}B{sub 2} magnets consolidated at 873 K.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

CRADA/NFE-15-05779 Report: Fabrication of Large Area Printable Composite Magnets

The technical objective of this technical collaboration phase I proposal was to fabricate large area NdFeB composite magnets at the Oak Ridge National Laboratory Manufacturing Demonstration Facility (ORNL MDF). The goal was to distribute domestically produced isotropic and highly anisotropic high energy density magnetic particles throughout the composite structure in order to enable site specific placement of magnetic phases and minimize the generated waste associated with permanent magnet manufacturing. Big area additive manufacturing (BAAM) and magnet composite fabrication methods were used in this study. BAAM was used to fabricate 65 vol % isotropic MQP NdFeB magnets in nylon polymer matrix. BAAM magnet cylinder was sliced to two magnetic arc-shaped braces. The density of the small BAAM magnet pieces reached 4.1 g/cm 3 , and the room temperature magnetic properties are: Intrinsic coercivity H ci = 8.8 kOe, Remanence B r = 4.2 kG, and energy product (BH) max = 3.7 MGOe. Also, 1.5” x 1.5” composite magnets with anisotropic MQA NdFeB magnet in a resin were also fabricated under magnetic field. The unaligned sample had a density of 3.75 g/cm 3 . However, aligned sample possessed a density of 4.27 g/cm 3 . The magnetic properties didn’t degrade during this process. This study provides a pathway for preparing composite magnets for various magnetic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Design of a modified Halbach magnet for the CBETA Project

A modified Halbach magnet has been designed to be installed in the splitter/merger section of the CBETA project which is under construction at Cornell University. The splitter/merger of the CBETA consists of 4 beam lines and is shown in Fig. 1. Two of the functions of the splitter/merger lines are; first to match the beam parameters at the exit of the Energy Recovery Linac (ERL) to those at the entrance of the Fixed Field Alternating Gradient (FFAG) arc, and second to place the trajectories of the reference particles of the beam bunches at the entrance of the FFAG arc on specified trajectories as they determined by the beam optics of the FFAG arc. In this technical note we present results from the 2D and 3D electromagnetic analysis of the S4.BEN01 magnet which is one of the dipole magnets of the 150 MeV line of the splitter/merger. The present design of the S4.BEN01 magnet, is based on a modified Halbach-type permanent magnet. To justify our suggestion of using a Halbach type of magnet instead of an electromagnet for the S4.BEN01 magnet we devote an APPENDIX A in which we provide details on the design of an electromagnet for the S4.BEN01 magnet and in the section under conclusion will list the pros and cons of the two designs.

43 PARTICLE ACCELERATORS↗

DOE OSTI2017

Measurement of first magnet made with production material

The first CBETA magnet to be made using the production run of permanent magnet wedges is the BDH magnet, a “half length BD” to be placed at the start of the first girder of the FFAG return loop. This magnet has identifier number 2731 and is shown in the picture below while being prepared for measurement.

43 PARTICLE ACCELERATORS↗

NASA NTRS1992

Large-gap magnetic positioning system having advantageous configuration

A magnetic configuration was devised in which the positioned object is maintained in a stable orientation and position on one side of an opaque plane surface entirely by means of magnetic components on the other side of the plane. The system is effective with or without gravity, and can operate in any orientation. In this system, the positioned object need only contain a simple dipole magnet. The positioning components consist of a group of permanent magnets creating a magnetic field configuration which stabilizes the levitated dipole in all but one degree of freedom, and a magnetic position sensing and force feedback system to actively stabilize the object in the one unstable direction. The system utilizes very low power at equilibrium and can maintain gaps of 50 mm.

Chong, Paul↗

NASA NTRS1993

Radiation and temperature effects on electronic components investigated under the CSTI high capacity power project

The effects of nuclear radiation and high temperature environments must be fully known and understood for the electronic components and materials used in both the Power Conditioning and Control subsystem and the reactor Instrumentation and Control subsystem of future high capacity nuclear space power systems. This knowledge is required by the designer of these subsystems in order to develop highly reliable, long-life power systems for future NASA missions. A review and summary of the experimental results obtained for the electronic components and materials investigated under the power management element of the Civilian Space Technology Initiative (CSTI) high capacity power project are presented: (1) neutron, gamma ray, and temperature effects on power semiconductor switches, (2) temperature and frequency effects on soft magnetic materials; and (3) temperature effects on rare earth permanent magnets.

Schwarze, Gene E.↗

NASA NTRS1996

Intracellular magnetophoresis of amyloplasts and induction of root curvature

High-gradient magnetic fields (HGMFs) were used to induce intracellular magnetophoresis of amyloplasts. The HGMFs were generated by placing a small ferromagnetic wedge into a uniform magnetic field or at the gap edge between two permanent magnets. In the vicinity of the tip of the wedge the dynamic factor of the magnetic field, delta(H2/2), was about 10(9) Oe2.cm-1, which subjected the amyloplasts to a force comparable to that of gravity. When roots of 2-d-old seedlings of flax (Linum usitatissimum L.) were positioned vertically and exposed to an HGMF, curvature away from the wedge was transient and lasted approximately 1 h. Average curvature obtained after placing magnets, wedge and seedlings on a 1-rpm clinostat for 2 h was 33 +/- 5 degrees. Roots of horizontally placed control seedlings without rotation curved about 47 +/- 4 degrees. The time course of curvature and changes in growth rate were similar for gravicurvature and for root curvature induced by HGMFs. Microscopy showed displacement of amyloplasts in vitro and in vivo. Studies with Arabidopsis thaliana (L.) Heynh. showed that the wild type responded to HGMFs but the starchless mutant TC7 did not. The data indicate that a magnetic force can be used to study the gravisensing and response system of roots.

Non-NASA Center↗

NASA NTRS2013

External Magnetic Field Reduction Techniques for the Advanced Stirling Radioisotope Generator

Linear alternators coupled to high efficiency Stirling engines are strong candidates for thermal-to-electric power conversion in space. However, the magnetic field emissions, both AC and DC, of these permanent magnet excited alternators can interfere with sensitive instrumentation onboard a spacecraft. Effective methods to mitigate the AC and DC electromagnetic interference (EMI) from solenoidal type linear alternators (like that used in the Advanced Stirling Convertor) have been developed for potential use in the Advanced Stirling Radioisotope Generator. The methods developed avoid the complexity and extra mass inherent in data extraction from multiple sensors or the use of shielding. This paper discusses these methods, and also provides experimental data obtained during breadboard testing of both AC and DC external magnetic field devices.

Thermoelectric Power Generation↗

DOE OSTI2013

Magnetic bearing element with adjustable stiffness

A compact magnetic bearing element is provided which is made of permanent magnet discs configured to be capable of the adjustment of the bearing stiffness and levitation force over a wide range.

42 ENGINEERING↗

DOE OSTI2014

Microstructure and Magnetic Properties of Bulk Nanocrystalline MnAl

MnAl is a promising rare-earth free permanent magnet for technological use. We have examined the effects of consolidation by back-pressure, assisted equal channel angular extrusion processing on mechanically-milled, gas-atomized Mn-46% at. Al powder. X-ray diffraction showed both that the extruded rod consisted mostly of metastable tau phase, with some of the equilibrium gamma(2) and beta phases, and that it largely retained the as-milled nanostructure. Magnetic measurements show a coercivity of <= 4.4 kOe and a magnetization at 10 kOe of <= 40 emu/g. In addition, extrusions exhibit greater than 95% of the theoretical density. This study opens a new window in the area of bulk MnAl magnets with improved magnetic properties for technological use.

Chaturvedi, A↗

DOE OSTI2014

WE-D-17A-04: Magnetically Focused Proton Irradiation of Small Volume Targets

Purpose: To explore the advantages of magnetic focusing for small volume proton irradiations and the potential clinical benefits for radiosurgery targets. The primary goal is to create narrow elongated proton beams of elliptical cross section with superior dose delivery characteristics compared to current delivery modalities (eg, collimated beams). In addition, more general beam shapes are also under investigation. Methods: Two prototype magnets consisting of 24 segments of samarium-cobalt (Sm2Co17) permanent magnetic material adhered into hollow cylinders were manufactured for testing. A single focusing magnet was placed on a positioning track on our Gantry 1 treatment table and 15 mm diameter proton beams with energies and modulation relevant to clinical radiosurgery applications (127 to 186 MeV, and 0 to 30 mm modulation) were delivered to a terminal water tank. Beam dose distributions were measured using a PTW diode detector and Gafchromic EBT2 film. Longitudinal and transverse dose profiles were analyzed and compared to data from Monte Carlo simulations analogous to the experimental setup. Results: The narrow elongated focused beam spots showed high elliptical symmetry indicating high magnet quality. In addition, when compared to unfocused beams, peak-to-entrance depth dose ratios were 11 to 14% larger (depending on presence or extent of modulation), and minor axis penumbras were 11 to 20% smaller (again depending on modulation) for focused beams. These results suggest that the use of rare earth magnet assemblies is practical and could improve dose-sparing of normal tissue and organs at risk while delivering enhanced dose to small proton radiosurgery targets. Conclusion: Quadrapole rare earth magnetic assemblies are a promising and inexpensive method to counteract particle out scatter that tends to degrade the peak to entrance performance of small field proton beams. Knowledge gained from current experiments will inform the design of a prototype treatment nozzle that incorporates similar focusing magnets. This project was sponsored in part by funding from the Department of Defense (DOD# W81XWH-BAA-10-1)

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

LandRAY PTO Testing Utilizing the NREL NWTC 5MW Dynamometer

The overarching project objective is to demonstrate the feasibility of using an innovative PowerTake-Off (PTO) Module in Columbia Power's utility-scale wave energy converter (WEC). The PTO Module uniquely combines a large-diameter, direct-drive, rotary permanent magnet generator; a patent-pending rail-bearing system; and a corrosion-resistant fiber-reinforced-plastic structure

16 TIDAL AND WAVE POWER↗

DOE OSTI2017

Two design of the S4.BEN01 magnet for the CBETA splitter/merger

The splitter/merger section of the CBETA project [1] consists of 4 beam lines as shown in Fig. 1. Two of the functions of the splitter’s/merger’s lines is to match the beam parameters at the exit of the Energy Recovery Linac (ERL) to the beam parameters at the entrance of the Fixed Field Alternating Gradient (FFAG) arc, and also place the reference particles of the beam bunches at the entrance of the FFAG arc on specified trajectories according to their energies. In this technical note we are presenting results from the 2D and 3D electromagnetic analysis of the S4.BEN01 magnet which is one of the dipole magnets of the 150 MeV line of the splitter/merger. In particular we present results from two designs of the S4.BEN01 magnet, one based on iron dominated current-excited magnet, and the other design based on Halbach-type permanent magnet. An evaluation of the two designs will be given in the section under “conclusion”.

43 PARTICLE ACCELERATORS↗