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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

High-Fidelity Modeling of a Type-5 Wind Turbine Gearbox (Intern Poster) [Poster]

Type-5 wind turbines are unique in their use of a permanent magnet synchronous generator, as well as their use of a hydraulic torque converter. This architecture presents an opportunity to provide steady and grid-ready energy without the need for a power converter. With infrastructure continuity and reliability being an important topic amongst renewable energies, researchers have been prompted to further investigate the benefits of type-5 turbines’ unique electromechanical configuration on stable electricity generation. Researchers involved in the WindSG project, SG standing for synchronous generator, are aiming to model a type-5 turbine using Real Time Digital Simulation (RTDS) to evaluate its efficacy in the grid. RSCAD, the software run on the RTDS, comes pre-loaded with electrical and electromechanical components to help simulate electrical generation and grid conditions. However, within this repertoire there is a lack of a component to represent a gearbox with high-fidelity. Within RSCAD’s case studies, the gearbox is often represented simply by a gear ratio value. This presented the task of developing a high-fidelity gearbox model in RSCAD for use in the larger RTDS type-5 wind turbine model. This poster describes a method of developing a lumped parameter mathematical model to represent a planetary-parallel-parallel gearbox in RSCAD for use in RTDS.

17 WIND ENERGY↗
DOE OSTI2024

Design and Optimization of Processes for Recovering Rare Earth Elements from End-of-Life Hard Disk Drives

In this poster, we first provide motivation for why rare earth elements as rare earth permanent magnets (REPM) are increasing in demand. We then highlight some of the recent work that has been done by several national labs (National Renewable Energy Laboratory (NREL), Environmental Protection Agency (EPA), Critical Minerals Institute (CMI)) on recycling rare earth elements from end-of-life hard disk drives (EOL). Then, we mention our long-term plan to design a feedstock agnostic process to recover rare earth elements as rare earth oxides from many different EOL products at once. Next, we discuss how we quantified the rare earth elements available for recycling from EOL hard disk drives from consumer desktops and laptops. We then discuss how we used superstructure optimization to design the optimal pathway. The proposed superstructure was modeled as a MILP optimization problem, selecting the net present value as the objective function. Costing data from the literature was used to inform this model whenever possible. However, due to the novelty of this research area, data were often unavailable, thus requiring the generation of flowsheets implemented in Aspen Plus.

Laliwala, Chris↗
DOE OSTI2024

High-Fidelity Modeling of a Type-5 Wind Turbine Gearbox (Intern Technical Presentation) (Poster)

Type-5 wind turbines are unique in their use of a permanent magnet synchronous generator, as well as their use of a hydraulic torque converter. This architecture presents an opportunity to provide steady and grid-ready energy without the need for a power converter. With infrastructure continuity and reliability being an important topic amongst renewable energies, researchers have been prompted to further investigate the benefits of type-5 turbines’ unique electromechanical configuration on stable electricity generation. Researchers involved in the WindSG project, SG standing for synchronous generator, are aiming to model a type-5 turbine using Real Time Digital Simulation (RTDS) to evaluate its efficacy in the grid. RSCAD, the software run on the RTDS, comes pre-loaded with electrical and electromechanical components to help simulate electrical generation and grid conditions. However, within this repertoire there is a lack of a component to represent a gearbox with high-fidelity. Within RSCAD’s case studies, the gearbox is often represented simply by a gear ratio value. This presented the task of developing a high-fidelity gearbox model in RSCAD for use in the larger RTDS type-5 wind turbine model. This presentation describes a method of developing a lumped parameter mathematical model to represent a planetary-parallel-parallel gearbox in RSCAD for use in RTDS.

17 WIND ENERGY↗
DOE OSTI2025

Foil Bearing Supported Compressor-Expander

R&D Dynamics Corporation (RDD) is developing a fuel cell system compressor-expander designed for heavy-duty vehicle applications. The system emphasizes high reliability, versatility, long service life, and cost-effective mass production. Its design integrates a high-speed centrifugal compressor/expander, oil-free foil air/gas bearings, a direct current permanent magnet (DCPM) motor, and an inverter utilizing silicon carbide (SiC) switches. Key advantages include high efficiency, compact size and reduced weight, enhanced reliability, and elimination of oil contamination risks. The technology targets multiple sectors such as long-haul semi-trucks, mining and construction equipment, power generation, data centers, marine systems, and other heavy machinery. Evaluation units are ready for shipment, and manufacturing capabilities are currently being developed. Contract Number: DE-EE0009617 (2021).

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

High power density compact drive integrated motor for electric transportation

This project, initially part of OPEN 2018, and subsequently the ASCEND effort, targeted demonstration of significant enhancements in internal permanent magnet (IPM) motor torque and power density for current and future ground and air electric transportation applications. These were achieved through: (1) embedded two-phase system thermal management, (2) coupled, multi-scale electrical-electromagnetic-thermal-mechanical co-design and optimization, (3) size and weight reduction of motor and drive electronics through elimination of redundant cooling and coupling hardware, and (4) higher efficiency operation of SiC wide bandgap power electronics packaging through high temperature operation (200 oC). The proposed approach utilizes a single dielectric coolant for closed loop two-phase thermal management, and a combined heat rejection unit for the IPM and drive. Wick assisted liquid delivery for evaporative thermal management is utilized for the motor, and the drive electronics utilize the same coolant in flow boiling within the cold plate structures. Through the use of three-dimensional packaging for SiC, and novel drive topologies with reduced switching losses, significant increases in power density and compactness were targeted.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Novel Modular Heat Engines with sCO 2 Bottoming Cycle Utilizing Advanced Oil-Free Turbomachinery

This report presents the thermal, mechanical, and electric machine design of a 27krpm rotating test rig aimed at reducing technical risks with hermetic oil-free super-critical carbon dioxide (sCO 2 ) turbomachinery. The test rig rotor system is based on a conceptual turbomachine design discussed that evaluates a sCO 2 waste heat recovery (WHR) unit for land-based gas turbines at natural gas (NG) compressor stations. The key novelty of the hermetic sCO 2 turbomachine concept is the utilization of additively manufactured CO 2 gas bearings and a CO 2 -immersed direct-drive permanent magnet (PM) electric machine. The previous effort on conceptual design identified 3 main technical risks, which included thrust bearing load capacity, rotordynamics, and thermal performance of the system. Therefore, key requirements of the test vehicle include the ability to test the rotor system in a 400psi (27.6 bar) hermetic CO 2 operating environment, apply up to 1,500 lbs (6.7 kN) of rotor thrust loads, capability to assess rotordynamics with radial gas bearings, inclusion of instrumentation to assess thrust bearing load capability, and flexibility for varying secondary cooling flows to confirm thermal model predictions. Design topics such as rotordynamics, bearing design, and electric machine design are addressed, while highlighting critical elements. In addition, additive build trials for Inconel 718 radial and thrust bearings were performed to prove the manufacturability of the bearing design concepts. The results of the design efforts yield a test rig concept with ability to operate at 27,000 rpm, apply thrust loads to 1,500 lbs, deliver CO 2 up to 800psi, and modulate cooling flows.

03 NATURAL GAS↗
DOE OSTI2025

Cold Spray Cobalt Magnetostrictive Electromagnetic Acoustic Transducers for High Temperature Structure Monitoring

The Department of Energy’s Advanced Sensors and Instrumentation program seeks to develop and qualify advanced sensors for the nuclear industry. Reliable high temperature and high radiation sensors for detection and characterization of structural flaws in pipes, vessels, and structurally critical components is a weakness for both conventional light water reactors with coolant T-hot approaching 350oC, and for advanced reactors with T-hot temperatures in excess of 500 to 800oC. Magnetostrictive Electromagnetic Acoustic Transducers using a cold spray cobalt coating have been proposed as a sensor design that can withstand these kinds of temperatures and radiation levels to serve as online sensors to detect flaws before cracks, pits, or erosion/corrosion flaws progress to through-wall failures. This report tests cold spray cobalt as part of a magnetostrictive EMAT for high temperature service. Cobalt is known to have strong magnetostrictive properties however the effect of cold spray application is not well studied. This program was surprised to discover that cold sprayed cobalt exhibited little or no magnetostrictive behavior until it was thermally annealed. Following annealing to 650oC however, cold spray cobalt did exhibit a magnetostrictive response. Work to date prior to this milestone report publication showed that magnetostrictive EMAT was successfully tested to 400oC with an alnico permanent magnet. The program plans to extend testing with an electromagnet to higher temperatures. This follow-on work will be reported under subsequent publications or as a revision to this report.

Glass, Samuel W.↗
DOE OSTI2025

An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor

Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd2Fe14B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of combined function dipole-quadrupole PMQs magnets for NSLS-II upgrade

This paper focuses on the R&D performed for the development of permanent magnets-based dipoles-quadrupoles combined function magnets (PMQs) for the future NSLSII upgrade “complex bend” lattice (CB). This new lattice uses PMQs that provide both bending (dipole) and strong focusing (quadrupole) magnetic field on the electron beam. The permanent magnet (PM) technology is suitable for the high magnetic field strengths (0.5 T, 130 T/m) required for such combine function magnets. PM technology leads to a compact magnet design that is essential in realizing the complex bend lattice concept, as well as a passive magnet solution which does not require electrical power supply reducing power consumption by ~ 80% (from 1.7 MW to 0.3 MW for NSLS-II). Two PMQs magnets designs are under consideration: A hybrid design that use both PM and soft iron poles, and Halbach type that is a pure PM design. Both PMQs designs present challenges in achieving the specified magnetic field quality due to their higher sensitivity to errors (mechanical tolerances and PM properties). This paper presents cost-effective designs and prototypes results for hybrid and Halbach PMQs, addressing various technical challenges while meeting the field requirements of the complex bend lattice for the NSLS-II upgrade.

N'gotta, Patrick [Brookhaven]↗
DOE OSTI2026

Role of washing solvents in defining the magnetic performance of Sm 2 Fe 17 N 3 obtained by reduction diffusion

Calciothermic reduction-diffusion (RD) is one of the leading synthesis methods for Sm 2 Fe 17 N 3 (SmFeN), but sintering of such RD-derived powders is hampered by oxidation and CaO byproducts. Here, we systematically evaluate how post-synthesis washing solvents govern powder chemistry and magnetic performance. RD-synthesized SmFeN powder was washed with several aqueous and non-aqueous solvents using identical washing protocols. This was followed by an assessment of both the as-washed powder as well as after annealing at 425 °C. Phase content was quantified by synchrotron PXRD and Rietveld refinement and SEM/EDS. The oxygen content of the powders was determined via inert gas fusion and the magnetization by DC magnetometry. While all aqueous-based solutions were able to remove CaO, the non-aqueous solutions were only effective with extended washing times. Prior to annealing, the crystalline phases and magnetic properties of the as-washed powders were largely the same regardless of washing solvent. However, differences emerge after annealing, where water-based washing markedly lowers the coercivity (H c ~3.8-4.3 kOe). In contrast, non-aqueous NH 4 Cl-methanol washing protocols were more effective in preserving coercivity (H c ~4.9-5.9 kOe). We attribute this to lower oxygen content in the non-aqueous samples (~9,400 ppm v ~6,400 ppm, respectively) which in turn reduced the formation of α-Fe during annealing. These results highlight the importance of solvent choice in washing RD-synthesized SmFeN and demonstrate that non-aqueous protocols, which better limit oxidation, outperform aqueous solvents despite the need for longer washing times.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Selective capture and recovery of uranium oxide colloids from aqueous soil suspensions using high gradient magnetic filtration

High Gradient Magnetic Filtration (HGMF) is a promising method for the selective capture and recovery of uranium oxide from surface soils. To date, however, magnetic filtration of uranium oxide has only been demonstrated at a proof-of-principle scale using relatively small filters (<5 cm 3 ) at low flowrates (<60 mL/min). Here, to explore the efficacy of magnetic filtration of uranium oxide at a larger scale, a newly designed HGMF apparatus that is more than an order of magnitude larger than our earlier filters (106 cm 3 ) was designed, fabricated, and tested at relatively high flowrates. Filtration experiments were performed using aqueous uranium oxide particle suspensions with Arizona Road Dust (ARD) as a soil simulant. At a flowrate of 125 mL/min, the apparatus’ uranium capture rate was exceptionally high (96 %), but selectivity was poor due to the high rate of capture for diamagnetic soil constituents (e.g., 77 % for silicon). All particles were captured at a lower rate when the flowrate was increased to 250 mL/min, but uranium selectivity was significantly increased due to the more substantial reduction in diamagnetic particle capture (i.e., capture rate of 77 % and 15 % for uranium and silicon, respectively). When backwashing the apparatus at the same flowrates used during filtration experiments, the rate of uranium recovery tended to be fairly low. Nevertheless, higher flowrates (1 L/min) and sonication were both shown to be highly effective methods of increasing uranium recovery. Magnetic field simulations were also performed to investigate potential optimizations to the design of the apparatus. These simulations showed that the intensity of the applied magnetic field could be increased by increasing the thickness of the steel magnetic housing. Additionally, stochastic trajectory simulations were performed to investigate the potential mechanisms of particle capture.

HGMF↗
DOE OSTI2024

On the origin of magnetic anisotropy in 4f-free ferromagnets based on the CaCu 5 structure *

Using first-principles calculations, we investigate the origin of magnetocrystalline anisotropy in a series of 4f-electron-free intermetallics with CaCu 5 -based structures: YCo 5 , YCo 4 B, and Y 3 Co 13 B 2 . The electronic structure of these compounds is characterized by a set of narrow 3d bands near the Fermi level. In YCo 5 the easy-axis anisotropy originates primarily in the spin–orbit coupling-induced mixing of the electronic states with Co d x 2 -y 2 and d xy character. The analysis of k-resolved anisotropy shows that positive contributions accumulate from the entire Brillouin zone but are particularly large near the k z = 0 plane. The analysis of the single-site and two-site terms reveals a large positive single-site contribution to the magnetocrystalline anisotropy from the Co atoms on the honeycomb sublattice, along with two-site contributions from both honeycomb and kagome sublattices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Quadrupole wiggler for a collinear wakefield accelerator

A quadrupole wiggler consisting of a row of alternating-polarity permanent magnet-excited quadrupoles is used in a collinear wakefield accelerator under development at Argonne National Laboratory. Fine translational and angular adjustment mechanisms are implemented in all quadrupoles to obtain a better than 1−μ⁢m precision in the alignment of quadrupole wiggler assemblies. The quadrupole’s magnetic and mechanical designs are described. Two wiggler prototypes were fabricated, aligned, and characterized performing pulsed wire magnetic measurements. The sensitivity of the quadrupole wiggler alignment to the ambient temperature was measured.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Technological developments and accelerator improvements for the FRIB beam power ramp-up

The Facility for Rare Isotope Beams (FRIB) began operation with 1 kW beam power for scientific users in May 2022 upon completion of 8 years of project construction. The ramp-up to the ultimate beam power of 400 kW, planned over a 6-year period, will enable the facility to reach its full potential for scientific discovery in isotope science and applications. In December 2023, a record-high beam power of 10.4 kW uranium was delivered to the target. Technological developments and accelerator improvements are being made over the entire facility and are key to completion of the power ramp-up. Major technological developments entail the phased deployment of high-power beam-intercepting systems, including the charge strippers, the charge selection systems, the production target, and the beam dump, along with support systems, including non-conventional utilities (NCU) and remote handling facilities. Major accelerator improvements include renovations to aging legacy systems associated with experimental beam lines and system automation for improved operational efficiency and better machine availability. Experience must be gained to safely handle the increased radiological impacts associated with high beam power; extensive machine studies and advanced beam tuning procedures are needed to minimize uncontrolled beam losses for the desired operating conditions. This paper discusses the technological developments and accelerator improvements with emphasis on major R&D efforts.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Crystal structure and magnetic properties of CeFe 11 M (M = Mo, W)

Tetragonal CeFe 11 Mo (struct. type ThMn 12 , a = 8.529(1) Å, c = 4.766(1) Å, V = 346.68(1) Å 3 ) and novel isostructural CeFe 11 W (a = 8.539(1) Å, c = 4.754(1) Å, V = 346.62(1) Å 3 ) are obtained in bulk, as homogenized single-phase arc-melted alloys. Here, their crystal structures are evaluated by full profile Rietveld analysis of the powder X-ray diffraction patterns which confirm that Ce occupies the 2a atomic site in both cases, whereas atomic disorder is present in the Fe-sublattice, i.e., predominantly on the dumbbell 8i site and minorly on two other sites 8j and 8f. In CeFe 11 Mo the third element, M, is mixed with Fe on the 8i dumbbell site and 8f atomic position, whereas in CeFe 11 W, M is mixed on the 8i and 8j Fe sites. In these bulk CeFe 12-x M x alloys the tetragonal structure persists at lower M content, x < 1 here, in comparison to known similar alloys, with x > 1. Because of the low M content, comparably higher values of mass magnetization and Curie temperature are achieved i.e., CeFe 11 Mo: ϭ s = 104 emu/g (14.7 µ B /f.u.), T c = 420 K and CeFe 11 W: ϭ s = 99 emu/g (16.5 µ B /f.u.), T c = 450 K. Magnetocrystalline anisotropy is uniaxial with anisotropy fields H a ∼ 14.5 and 16.5 kOe, respectively. Based on Curie temperature and magnetic anisotropy enhancements, using tungsten as the stabilizing dopant is more beneficial than molybdenum.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bulk magnetic hardening in Sm(Fe,V) 12 alloys

Cast Sm-Fe-V magnets with the tetragonal crystal structure of the ThMn 12 type were prepared with high coercivity through a two-step annealing at 775°C and then at 825°C. The annealing processing used allowed us for the first time to successfully produce a large amount of non-magnetic Sm-rich grain-boundary phase in Sm-Fe-V cast ingots. As a result, the sample with composition Sm 11.1 Fe 75.8 V 13.1 showed the record-high coercivity (6.66 kOe) after annealing at 775°C for 72 h and then 825°C for 2 h. Furthermore, this coercivity, achieved without the use of powder metallurgy, has nearly doubled compared to the previously reported highest value of 3.70 kOe in a cast SmFe 10 V 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2025

Implementation of Advanced Grid Support Functionalities by Smart Operation of Residential Loads with low Cost Converter Interface

This paper investigates a grid-supportive load concept for small-scale residential appliances, focusing on a residential refrigerator. Power consumption is adjusted based on grid conditions to achieve IEEE-1547 grid support functions. Two key aspects are presented: a low-cost refrigerator converter with Lyapunov energy function-based local controllers for speed control, and the impact on a standard microgrid system, demonstrating advanced grid support from the load side. This method enhances grid resilience and reliability and can be extended to other residential loads. The study contributes to efficient and robust grid-supportive load management systems, showing promising performance. This approach has the potential to improve overall grid stability and can be adapted for various types of residential appliances. The modeling and simulations in MATLAB/Simulink and PLECS confirm the feasibility and effectiveness of the proposed solution. Future work will explore real-world implementation and scalability of this concept for broader applications.

grid supportive loads (GSL)↗
DOE OSTI2024

Summary of Jefferson Lab LDRD on FFA@CEBAF Beam Dynamics Simulations

As Thomas Jefferson National Accelerator Facility (Jefferson Lab) looks toward the future, we are considering expanding our energy reach by using Fixed-Field Alternating Gradient (FFA) technology. Significant efforts have been made to design a hybrid accelerator which combines conventional recirculating electron LINAC design with permanent magnet-based FFA technology to increase the number of beam recirculations, and thus the energy. In an effort to further this progress, Jefferson Lab awarded a Laboratory Directed Research and Development (LDRD) grant to focus not on the design, but on detailed simulations of the designs created by the larger collaboration. This document will summarize the work performed during this LDRD, and direct the reader to other proceedings which describe elements of the work in greater detail.

Deitrick, K.↗