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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 991 records · Page 55
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Studies on in situ magnetic alignment of bonded anisotropic Nd-Fe-B alloy powders

We presented some considerations for achieving high degree of alignment in polymer bonded permanent magnets via the results of a study on in situ magnetic alignment of anisotropic Nd-Fe-B magnet powders. Contributions from effect of the alignment temperature, alignment magnetic field and the properties of the polymer on the hard magnetic properties of the bonded magnet were considered. Moreover, the thermo-rheological properties of the polymer and the response of the magnet powders to the applied magnetic field indicate that hard magnetic properties were optimized at an alignment temperature just above the melting temperature of the EVA co-polymer. This agrees with an observed correlation between the change in magnetization due to improved magnetic alignment of the anisotropic powders and the change in viscosity of the binder. Finally, manufacturing cost can be minimized by identifying optimum alignment temperatures and magnetic field strengths.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Structural and magnetic properties of the CeCo 5 –CeZn 5 solid solution and potential improvements upon iron substitution

In an effort to create high-performance permanent magnets with reduced critical rare earth content, we explored the CeCo 5-x T x (T = transition metal or metalloid) family of compounds to investigate the effect of substitution on the material’s magnetic properties. In our exploration of the CeCo 5-x Zn x system, we discovered a continuous solid solution at 900 °C between the CeCo 5 and CeZn 5 binary phases with ferromagnetism existing from the CeCo 5 compound to the intermediate CeCo 2.75 Zn 2.25 compound. Single crystal studies were also conducted revealing a relatively large anisotropy field of 11.5 T at 300 K for Ce 0.96 Ta 0.04 Co 4.35 Zn 0.65 . Here, the addition of iron Ce 0.79 Ta 0.07 Co 3.77 Fe 0.89 Zn 0.47 yielded further increases in Curie temperature and saturation magnetization to 800 K and 85.5 emu/g, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1989

Analytical model of a five degree of freedom magnetic suspension and positioning system

An analytical model of a five degree of freedom magnetic suspension and positioning system is presented. The suspended element is a cylinder which is composed of permanent magnet material and the magnetic actuators are air core electromagnets mounted in a planar array. The analytical model consists of an open loop representation of the suspension and positioning system with electromagnet currents as inputs and displacements and rates in inertial coordinates as outputs. The uncontrolled degree of freedom is rotation about the long axis of the suspended cylinder.

Groom, Nelson J.↗
DOE OSTI2013

Novel Nanostructured Rare-Earth-Free Magnetic Materials with High Energy Products

Novel nanostructured Zr 2 Co 11 –based magnetic materials are fabricated in a single step process using cluster–deposition method. Here, the composition, atomic ordering, and spin structure are precisely controlled to achieve a substantial magnetic remanence and coercivity, as well as the highest energy product for non–rare–earth and Pt–free permanent–magnet alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

MADE3D: Enabling the next generation of high-torque density wind generators by additive design and 3D printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments—especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technolgies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

17 WIND ENERGY↗
DOE OSTI2014

Magnetic-film atom chip with 10 μm period lattices of microtraps for quantum information science with Rydberg atoms

We describe the fabrication and construction of a setup for creating lattices of magnetic microtraps for ultracold atoms on an atom chip. The lattice is defined by lithographic patterning of a permanent magnetic film. Patterned magnetic-film atom chips enable a large variety of trapping geometries over a wide range of length scales. We demonstrate an atom chip with a lattice constant of 10 μm, suitable for experiments in quantum information science employing the interaction between atoms in highly excited Rydberg energy levels. The active trapping region contains lattice regions with square and hexagonal symmetry, with the two regions joined at an interface. A structure of macroscopic wires, cutout of a silver foil, was mounted under the atom chip in order to load ultracold {sup 87}Rb atoms into the microtraps. We demonstrate loading of atoms into the square and hexagonal lattice sections simultaneously and show resolved imaging of individual lattice sites. Magnetic-film lattices on atom chips provide a versatile platform for experiments with ultracold atoms, in particular for quantum information science and quantum simulation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2003

NASA GRC Stirling Technology Development Overview

The Department of Energy, Lockheed Martin (LM), Stirling Technology Company, and NASA Glenn Research Center (GRC) are developing a high-efficiency Stirling Radioisotope Generator (SRG) for potential NASA Space Science missions. The SRG is being developed for multimission use, including providing spacecraft onboard electric power for NASA deep space missions and power for unmanned Mars rovers. NASA GRC is conducting an in- house supporting technology project to assist in developing the Stirling convertor for space qualification and mission implementation. Preparations are underway for a thermalhacuum system demonstration and unattended operation during endurance testing of the 55-We Technology Demonstration Convertors. Heater head life assessment efforts continue, including verification of the heater head brazing and heat treatment schedules and evaluation of any potential regenerator oxidation. Long-term magnet aging tests are continuing to characterize any possible aging in the strength or demagnetization resistance of the permanent magnets used in the linear alternator. Testing of the magnet/lamination epoxy bond for performance and lifetime characteristics is now underway. These efforts are expected to provide key inputs as the system integrator, LM, begins system development of the SRG. GRC is also developing advanced technology for Stirling convertors. Cleveland State University (CSU) is progressing toward a multi-dimensional Stirling computational fluid dynamics code, capable of modeling complete convertors. Validation efforts at both CSU and the University of Minnesota are complementing the code development. New efforts have been started this year on a lightweight convertor, advanced controllers, high-temperature materials, and an end-to-end system dynamics model. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems.

Thieme, Lanny G.↗
NASA NTRS2011

Levitated Duct Fan (LDF) Aircraft Auxiliary Generator

This generator concept includes a novel stator and rotor architecture made from composite material with blades attached to the outer rotating shell of a ducted fan drum rotor, a non-contact support system between the stator and rotor using magnetic fields to provide levitation, and an integrated electromagnetic generation system. The magnetic suspension between the rotor and the stator suspends and supports the rotor within the stator housing using permanent magnets attached to the outer circumference of the drum rotor and passive levitation coils in the stator shell. The magnets are arranged in a Halbach array configuration.

Eichenberg, Dennis J.↗
NASA NTRS2003

Overview of NASA GRC Stirling Technology Development

The Stirling Radioisotope Generator (SRG) is currently being developed by Lockheed Martin Astronautics (LMA) under contract to the Depar1ment of Energy (DOE). The generator will be a high efficiency electric power source for NASA Space Science missions with the capability to operate in the vacuum of deep space or in an atmosphere such as on the surface of Mars. High system efficiency is obtained through the use of free-piston Stirling power conversion technology. Power output of the generator will be greater than 100 watts at the beginning of life with the decline in power being largely due to the decay of the plutonium heat source. In suppOl1 of the DOE SRG project, the NASA Glenn Research Center (GRC) has established a near-term technology effort to provide some of the critical data to ensure a successful transition to flight for what will be the first dynamic power system used in space. Initially, a limited number of technical areas were selected for the GRC effort, however this is now being expanded to more thoroughly cover a range of technical issues. The tasks include in-house testing of Stirling convertors and controllers, materials evaluation and heater head life assessment, structural dynamics, electromagnetic interference, organics evaluation, and reliability analysis. Most of these high-level tasks have several subtasks within. There is also an advanced technology effort that is complementary near-term technology effort. Many of the tests make use of the 55-We Technology Demonstration Convel10r (TDC). There have been multiple controller tests to support the LMA flight controller design effort. Preparation is continuing for a thermal/vacuum system demonstration. A pair of flight prototype TDC's have recently been placed on an extended test with unattended, continuous operation. Heater head life assessment efforts continue, with the material data being refined and the analysis moving toward the system perspective. Long-term magnet aging tests are continuing to characterize any possible aging in the strength or demagnetization resistance of the permanent magnets used in the linear alternator. In a parallel effort, higher performance magnets are also being evaluated. A reliability effort is being initiated that will help to guide the development activities with an increased focus on the necessary components and subsystems. Some other disciplines that are active in the GRC technology effort include structural dynamics, linear alternator analysis, EMI/EMC, controls, and mechanical design evaluation. This paper will provide an overview of some of the GRC technical efforts, including the current status, and a description of future efforts.

Schreiber, Jeffrey↗
DOE OSTI2021

MADE3D: Enabling the Next-Generation High-Torque- Density Wind Generators by Additive Design and 3D Printing

Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments - especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technologies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.

3D printing↗
DOE OSTI2013

Unexpected Magnetic Domain Behavior in LTP-MnBi

Low-temperature-phase MnBi (LTP-MnBi) has attracted much interest as a potential rare-earth-free permanent magnet material because of its high uniaxial magnetocrystalline anisotropy at room temperature, K approximate to 10(7) ergs/cc, and the unusual increase of anisotropy with increasing temperature, with an accompanying increasing coercive force (H-C) with temperature. However, due to the complex Mn-Bi phase diagram, bulk samples of LTP-MnBi with the optimum saturation moment, similar to 75-76 emu/g have been achieved only with zone-refined single crystals. We have prepared polycrystalline samples of LTP-MnBi by induction melting and annealing at 300 degrees C. The moment in 70 kOe is 73.5 emu/g, but H-C is only 50 Oe. This is quite surprising-the high saturation moment indicates the dominating presence of LTP-MnBi. Therefore, an H-C c of some significant fraction of 2K/M-S approximate to 30 kOe would seem reasonable in this polycrystalline sample. By examining "Bitter" patterns, we show that the sample is composed of similar to 50 - 100 mu m crystallites. The randomly oriented crystallites exhibit the variety of magnetic domain structures and orientations expected from the hexagonal-structured MnBi with its strong uniaxial anisotropy. Clearly, the reversal of magnetization in the sample proceeds by the low-field nucleation of reversed magnetization in each crystallite, rather than by a wall-pinning mechanism. When the annealed sample was milled into fine particles, H-C increased by several orders of magnitude, as expected.

Nguyen, PK↗
DOE OSTI2018

Transformation enabled nitride magnets absent rare earths and a process of making the same

A process for producing an ordered martensitic iron nitride powder that is suitable for use as a permanent magnetic material is provided. The process includes fabricating an iron alloy powder having a desired composition and uniformity; nitriding the iron alloy powder by contacting the material with a nitrogen source in a fluidized bed reactor to produce a nitride iron powder; transforming the nitride iron powder to a disordered martensitic phase; annealing the disordered martensitic phase to an ordered martensitic phase; and separating the ordered martensitic phase from the iron nitride powder to yield an ordered martensitic iron nitride powder.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Transformation enabled nitride magnets absent rare earths and a process of making the same

A process for producing an ordered martensitic iron nitride powder that is suitable for use as a permanent magnetic material is provided. The process includes fabricating an iron alloy powder having a desired composition and uniformity; nitriding the iron alloy powder by contacting the material with a nitrogen source in a fluidized bed reactor to produce a nitride iron powder; transforming the nitride iron powder to a disordered martensitic phase; annealing the disordered martensitic phase to an ordered martensitic phase; and separating the ordered martensitic phase from the iron nitride powder to yield an ordered martensitic iron nitride powder.

Matthiesen, David↗
DOE OSTI2015

A magnetic tunnel to shelter hyperpolarized fluids

To shield solutions carrying hyperpolarized nuclear magnetization from rapid relaxation during transfer through low fields, the transfer duct can be threaded through an array of permanent magnets. The advantages are illustrated for solutions containing hyperpolarized {sup 1}H and {sup 13}C nuclei in a variety of molecules.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Structural Characteristics and Phase Evolution of Calcium-Reduced (Sm,Zr)(Fe,Co,Ti) 12 Particles

Magnetic materials are essential for applications in electronics, energy conversion and many other industrial and technological sectors. Among the permanent magnets, rare-earth magnets exhibit the strongest properties and dominate the market shares in related applications. However, due to the increasing cost and unstable supply, the research on reducing the rare-earth elements in magnets attracts significant increasing interest. Rare-earth-lean samarium transition metal (TM) compounds (SmTM 12 or 1:12 for short) have made breakthroughs in 2020 and the (Sm,Zr)(Fe,Co,Ti) 12 monocrystalline particles synthesized by a Ca reduction of elemental oxides at high temperature demonstrated an order of magnitude improvement in coercivity at room temperature. In this study, we made structural analysis of (Sm,Zr)(Fe,Co,Ti) 12 particles to elucidate the impact of synthesis conditions, microstructure and phase transformation on the evolution of magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Initial performance of the magnet system in the splitter/combiner section of the Cornell-Brookhaven Energy-Recovery Linac Test Accelerator

The Cornell-Brookhaven Energy-recovery Linac Test Ac- celerator is a four-pass, 150-MeV electron accelerator with a six-cell 1.3 GHz superconducting-RF linear accelerator and a fixed-field alternating-gradient (FFAG) return loop made up of Halbach-style quadrupole magnets. The optics matching between the linear accelerator and the return loop is achieved with a conventional magnet system comprised of 50 dipole magnets and 64 quadrupole magnets in four beamlines at each end of the linac. The 42-, 78-, 114- and 150-MeV electron beams are separated into independent vacuum chambers in order to allow for the path-length ad- justment required by energy recovery. We report on the first beam tests of the initial installation of the splitter/combiner section at the exit of the linac. The vacuum system of the 42-MeV S1 line was installed during the first week of April. Nine dipole and four quadrupole magnets were installed and surveyed into position the following week, and the water cooling system was commissioned. A 6-MeV beam passed through the line on April 11 with no need for adjusting pre-set magnet excitation currents. One week later, time- of-flight measurements were used to calibrate and phase the individual superconducting RF cavities. The S1 magnet settings were then scaled up to achieve 5-cavity, 42-MeV operation through the first nine FFAG permanent-magnet quadrupoles. This initial Fractional Arc Test will conclude on May 18, when the installation of the remaining seven split- ter/combiner lines and the return loop will begin. CBETA operations are scheduled to begin in early 2019.

43 PARTICLE ACCELERATORS↗