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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Electromagnetic coil optimization for reduced Lorentz forces

Abstract The reduction of magnetic forces on electromagnetic coils is an important consideration in the design of high-field devices such as the stellarator or tokamak. Unfortunately, these forces may be too time-consuming to evaluate by conventional finite element modeling within an optimization loop. Although mutual forces can be computed rapidly by approximating large-bore coils as infinitely thin, this approximation does not hold for self-forces as it leads to an unphysical divergence. Recently, a novel reduced model for the self-field, self-force, and self-inductance of electromagnetic coils based on filamentary models was rigorously derived and demonstrated to be highly accurate and numerically efficient to evaluate (Hurwitz et al 2024 IEEE Trans. Magn. 60 7001614). In this paper, we present an implementation of the reduced self-force model employing automatic differentiation within the simsopt stellarator design software and use it in derivative-based coil optimization for a quasi-axisymmetric stellarator. We show that it is possible to significantly reduce point-wise forces throughout the coils, though this comes with trade-offs to fast particle losses and the minimum distance between coils and the plasma surface. The trade-off between magnetic forces and coil-surface distance is mediated by the minimum coil–coil distance for coils near the inboard side of the ‘bean’ cross-section of the plasma. The relationship between forces and fast particle losses is mediated by the normal field error. Coil forces can be lowered to a threshold with minimal deterioration to losses. Importantly, the magnet optimization approach here can be used also for tokamaks, other fusion concepts, and applications outside of fusion.

Hurwitz, Siena (ORCID:0000000166599659)↗
DOE OSTI2022

Calibration and Localization of Optically Pumped Magnetometers Using Electromagnetic Coils

In this paper, we propose a method to estimate the position, orientation, and gain of a magnetic field sensor using a set of (large) electromagnetic coils. We apply the method for calibrating an array of optically pumped magnetometers (OPMs) for magnetoencephalography (MEG). We first measure the magnetic fields of the coils at multiple known positions using a well-calibrated triaxial magnetometer, and model these discreetly sampled fields using vector spherical harmonics (VSH) functions. We then localize and calibrate an OPM by minimizing the sum of squared errors between the model signals and the OPM responses to the coil fields. We show that by using homogeneous and first-order gradient fields, the OPM sensor parameters (gain, position, and orientation) can be obtained from a set of linear equations with pseudo-inverses of two matrices. The currents that should be applied to the coils for approximating these low-order field components can be determined based on the VSH models. Computationally simple initial estimates of the OPM sensor parameters follow. As a first test of the method, we placed a fluxgate magnetometer at multiple positions and estimated the RMS position, orientation, and gain errors of the method to be 1.0 mm, 0.2°, and 0.8%, respectively. Lastly, we calibrated a 48-channel OPM array. The accuracy of the OPM calibration was tested by using the OPM array to localize magnetic dipoles in a phantom, which resulted in an average dipole position error of 3.3 mm. The results demonstrate the feasibility of using electromagnetic coils to calibrate and localize OPMs for MEG.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

The physical meaning of the magnetic scalar potential and its use in the design of hermetic electromagnetic coils

The magnetic scalar potential U(r⃗) has an intuitive physical interpretation, representing the electric current I = ΔU, which must be directed between any pair of isocontours along the boundary of a region, differing in potential by ΔU, in order to generate the corresponding magnetic intensity H⃗=−∇⃗U inside the region with no tangential component outside the boundary. This physical significance is exploited to invert the design process of hermetic (fringeless) electromagnetic coils from standard iterative techniques (calculating the magnetic field of refined current distributions) to a procedure for calculating the exact surface currents required to generate a given field configuration. A practical construction algorithm is given to produce the prescribed field in a “Target” region (constrained only by Maxwell’s equations) while confining the fringe field to a specified hermetic “Return” region. Example coils are analyzed along with a discussion of the limits of precision of the constructed field.

Crawford, C. B. (ORCID:0000000219324334)↗
DOE OSTI2022

Precise stellarator quasi-symmetry can be achieved with electromagnetic coils

Magnetic fields with quasi-symmetry are known to provide good confinement of charged particles and plasmas, but the extent to which quasi-symmetry can be achieved in practice has remained an open question. Recent work [M. Landreman and E. Paul, Phys. Rev. Lett. 128, 035001, 2022] reports the discovery of toroidal magnetic fields that are quasi-symmetric to orders-of-magnitude higher precision than previously known fields. We show that these fields can be accurately produced using electromagnetic coils of only moderate engineering complexity, that is, coils that have low curvature and that are sufficiently separated from each other. Our results demonstrate that these new quasi-symmetric fields are relevant for applications requiring the confinement of energetic charged particles for long time scales, such as nuclear fusion. The coils’ length plays an important role for how well the quasi-symmetric fields can be approximated. For the longest coil set considered and a mean field strength of 1 T, the departure from quasi-symmetry is of the order of Earth’s magnetic field. Additionally, we find that magnetic surfaces extend far outside the plasma boundary used by Landreman and Paul, providing confinement far from the core. Simulations confirm that the magnetic fields generated by the new coils confine particles with high kinetic energy substantially longer than previously known coil configurations. In particular, when scaled to a reactor, the best found configuration loses only 0.04% of energetic particles born at midradius when following guiding center trajectories for 200 ms.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Efficient calculation of self magnetic field, self-force, and self-inductance for electromagnetic coils with rectangular cross-section

Abstract For designing high-field electromagnets, the Lorentz force on coils needs to be computed in order to design suitable support structures, and the inductance should be computed to evaluate the stored energy and dynamics. Also, the magnetic field and its variation inside the conductor is of interest for computing stress and strain, and due to superconducting quench limits. For these force, inductance, energy, and internal field calculations, the coils cannot be naively approximated as infinitesimally thin filaments due to divergences when the source and evaluation points coincide, so more computationally demanding calculations are usually required, resolving the finite cross-section of the conductors. Here, we present a new alternative method that enables the internal magnetic field vector, self-force, and self-inductance to be computed rapidly and accurately within a 1D filament model. The method is applicable to coils for which the curve center-line can have general noncircular shape, as long as the conductor width is small compared to the radius of curvature. This paper extends a previous calculation for circular-cross-section conductors (Hurwitz et al 2024 IEEE Trans. Magn. ) to consider the case of rectangular cross-section. The reduced model is derived by rigorous analysis of the singularity, regularizing the filament integrals such that they match the true high-dimensional integrals at high coil aspect ratio. The new filament model exactly recovers analytic results for a circular coil, and is shown to accurately reproduce full finite-cross-section calculations for a non-planar coil of a stellarator magnetic fusion device. Due to the efficiency of the model here, it is well suited for use inside design optimization.

Landreman, Matt (ORCID:000000027233577X)↗
DOE OSTI2023

Direct stellarator coil optimization for nested magnetic surfaces with precise quasi-symmetry

We present a robust optimization algorithm for the design of electromagnetic coils that generate vacuum magnetic fields with nested flux surfaces and precise quasi-symmetry. The method is based on a bilevel optimization problem, where the outer coil optimization is constrained by a set of inner least squares optimization problems whose solutions describe magnetic surfaces. The outer optimization objective targets coils that generate a field with nested magnetic surfaces and good quasi-symmetry. The inner optimization problems identify magnetic surfaces when they exist, and approximate surfaces in the presence of magnetic islands or chaos. We show that this formulation can be used to heal islands and chaos, thus producing coils that result in magnetic fields with precise quasi-symmetry. We show that the method can be initialized with coils from the traditional two-stage coil design process, as well as coils from a near-axis expansion optimization. We present a numerical example where island chains are healed and quasi-symmetry is optimized up to surfaces with aspect ratio 6. Another numerical example illustrates that the aspect ratio of nested flux surfaces with optimized quasi-symmetry can be decreased from 6 to approximately 4. In conclusion, the last example shows that our approach is robust and a cold-start using coils from a near-axis expansion optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Stellarator fusion systems enabled by arrays of planar coils

We present an overview of a novel electromagnetic coil configuration for stellarators and its application to two near-term fusion systems. The novel coil configuration is the planar coil stellarator, able to implement precisely-quasisymmetric 3D magnetic fields using a set of planar, plasma-encircling coils and a set of planar, field-shaping coils situated on a surface surrounding the plasma. This configuration combines the stellarator’s advantages of steady-state operation, stability, low recirculating power fraction, and a mature physics basis, with the benefits of using simpler, planar coils which allow for a maintenance scheme leveraging large ports, and the ability to control magnets individually. The initial near-term use case considered is a steady state deuterium–deuterium stellarator neutron source, called Eos. The second near-term use case considered is a deuterium–tritium stellarator fusion pilot plant, called Helios, that would be approximately twice the linear dimension of the Eos design.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Including the vacuum energy in stellarator coil design

Being three-dimensional, stellarators have the advantage that plasma currents are not essential for creating rotational-transform; however, the external current-carrying coils in stellarators can have strong geometrical shaping, which can complicate the construction. Reducing the inter-coil electromagnetic forces acting on strongly shaped 3D coils and the stress on the support structure while preserving the favorable properties of the magnetic field is a design challenge. In this work, we recognize that the inter-coil forces are the gradient of the vacuum magnetic energy. We introduce an objective functional built on the usual quadratic flux on a prescribed target surface together with a weighed penalty on the vacuum energy. The Euler–Lagrange equation for stationary states is derived, and numerical illustrations are computed using a modern stellarator optimization framework. A study of the effect of the energy functional on the inter-coil forces is conducted and the energy is shown to be a promising quantity in producing coils with low forces.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Designing stellarators using perpendicular permanent magnets

We have developed a fast method to design perpendicular permanent magnets for simplifying stellarator coils based on existing codes. Coil complexity is one of the main challenges for stellarators. To date, only electromagnetic coils have been used to generate 3D fields for stellarators. Permanent magnets provide an alternative way to produce the desired magnetic field for optimized stellarators. In this paper, we revisit the concept of representing surface current using magnetic dipoles and carry out numerical validations. A surface magnetization is proven to be equivalent to the surface current that can be linearly solved by existing coil design codes. An incremental multi-layer method has been developed to obtain a practical solution that is attainable with present permanent magnets. With this method, we can reproduce a half-Tesla NCSX configuration using specially designed neodymium magnets together with simple planar coils. It shows that stellarator coils could be substantially simplified by adopting permanent magnets.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗
DOE OSTI2022

Stochastic and a posteriori optimization to mitigate coil manufacturing errors in stellarator design

Abstract It was recently shown in Wechsung et al (2022 Proc. Natl Acad. Sci. USA 119 e2202084119) that there exist electromagnetic coils that generate magnetic fields, which are excellent approximations to quasi-symmetric fields and have very good particle confinement properties. Using a Gaussian process-based model for coil perturbations, we investigate the impact of manufacturing errors on the performance of these coils. We show that even fairly small errors result in noticeable performance degradation. While stochastic optimization yields minor improvements, it is not possible to mitigate these errors significantly. As an alternative to stochastic optimization, we then formulate a new optimization problem for computing optimal adjustments of the coil positions and currents without changing the shapes of the coil. These a-posteriori adjustments are able to reduce the impact of coil errors by an order of magnitude, providing a new perspective for dealing with manufacturing tolerances in stellarator design.

Physics↗
DOE OSTI2025

Sensitivity of magnetic islands in permanent magnet stellarators using the gradient and Hessian methods

Stellarator plasmas are known to be very sensitive to perturbations in the magnetic field. The permanent magnet stellarator was in part developed as a solution to high machining tolerances placed on the shape properties of electromagnetic coils in traditional stellarators. However, as a consequence of this high sensitivity to the field structure, sensitivities of permanent magnet stellarator plasmas to perturbations of permanent magnet properties must necessarily be well-understood. The gradient and Hessian matrix methods have been previously demonstrated to be useful sensitivity analysis methods for modular coils. We apply these two methods to the study of island width sensitivities in both the MUSE and PM4STELL permanent magnet stellarator projects. These sensitivity methods were used to determine the relative impacts of permanent magnet parameter perturbations on island widths in the vacuum field approximation of both stellarator equilibria. The square of resonant magnetic field perturbation is used here as a proxy for island width. In particular, gradients of magnetizations of individual magnets were examined in MUSE, as well as gradients of magnet group displacements informed by device design. Three different forms of permanent magnet magnetization perturbations are investigated for MUSE, and the flux surface response to perturbations is demonstrated. The Hessian matrix method is applied to PM4STELL, illustrating the sensitivity of dominant island widths to displacements of toroidal wedge structures. These methods allow for selective direction of experimental resources toward regions of heightened sensitivity, while constraints on less impactful permanent magnet parameters can be relaxed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
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↗