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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

An Assessment of Additively Manufactured Bonded Permanent Magnets for a Distributed Wind Generator

In this paper, we examine and compare the performance of a generator design optimized using additively manufactured NdFeB-SmFeN in nylon-polymer-bonded permanent magnets (PMs) against a generator design with conventional NdFeB sintered PMs. To realize this, a commercially available 15-kW wind generator's rotor is re-optimized using both additively manufactured and sintered NdFeB magnets using simple geometric parameterization that allowed for two specific magnet shapes, namely, arc-shaped and crown-shaped designs. Results showed that for a similar generator performance, the designs with additively manufactured bonded PMs are more cost-competitive in terms of the estimated PM material cost and also have negligible eddy current magnet losses.

additive manufacturing↗

Advanced Permanent Magnet Generator Topologies Using Multimaterial Shape Optimization and 3D Printing: Preprint

A vast majority of utility-scale wind turbine generators in the United States are dependent on foreign- sourced rare-earth permanent magnets that are vulnerable to supply chain uncertainties. Many small wind original equipment manufacturers are motivated to pursue continuous improvements to the generator design to lower the material and production costs and improve performance by lowering cogging torque and increasing the efficiency. Traditional design and manufacturing offer limited opportunities. In this work, we demonstrate advanced design approaches for a 15-kW baseline wind turbine generator by making use of recent progress in three-dimensional (3D) printing of polymer- bonded magnets and, electrical and structural steel. We explore three methods of magnet parametrization using Bezier curves resulting in symmetric, asymmetric and multimaterial magnet designs. We employ a multiphysics approach combining parametric computer-aided design modeling, finite- element analysis and targeted sampling to identify novel designs with more opportunities for reducing rare-earth material, improving efficiency and minimizing cogging torque. The results show that asymmetric-pole design and multimaterial-pole designs offer a greater opportunity to minimize rare-earth magnet materials by up to 35% with similar performance as the baseline generator, suggesting newer opportunities with design freedom beyond traditional limits of symmetry and as allowed by 3D printing.

Bezier curves↗

Status of permanent magnet radiation resiliency studies at CEBAF

An ongoing investigation for the future of Jefferson Lab’s Continuous Electron Beam Accelerator Facility (CEBAF) lies in upgrading its maximum nominal energy using Fixed-Field Alternating-gradient (FFA) technology for its recirculating arcs, using permanent magnets for the FFA arcs. A common concern among the community is the degradation of these permanent magnets during operation due to the radiation environment in which they will be present. This work, funded by a Laboratory Directed R&D grant, aims to measure the permanent magnet degradation in the CEBAF tunnel enclosure, and extrapolate to the energies expected from the upgrade. We present the latest results of this study, as well as plans moving forward.

Accelerator Physics↗

Iron nitride permanent magnet and technique for forming iron nitride permanent magnet

A permanent magnet may include a Fe 16 N 2 phase constitution. In some examples, the permanent magnet may be formed by a technique that includes straining an iron wire or sheet comprising at least one iron crystal in a direction substantially parallel to a <001> crystal axis of the iron crystal; nitridizing the iron wire or sheet to form a nitridized iron wire or sheet; annealing the nitridized iron wire or sheet to form a Fe 16 N 2 phase constitution in at least a portion of the nitridized iron wire or sheet; and pressing the nitridized iron wires and sheets to form bulk permanent magnet.

Wang, Jian-Ping↗

Design and Comparison of Surface Inset Permanent Magnet Machine and Surface Permanent Magnet Machine without Heavy Rare Earth Magnets for Traction Applications

This paper presents two machine designs: a surface inset permanent magnet (SIPM) machine and a surface permanent magnet (SPM) machine, both without heavy rare-earth magnets, that achieve 50 kW/L active power density and a constant-power speed ratio of 3 for EV traction applications. Compared to surface PM machines, SIPM machines do not require a special containment sleeve to hold the magnets in place at high speeds, provided that the rotor laminations are carefully designed together with the magnet mounting configuration to ensure the rotor’s structural integrity. Comparisons between the SPM and SIPM machines sharing the same stator, same current level, and same power speed envelope are presented. Both deliver very similar performance characteristics, but the SIPM machine’s simpler magnet containment configuration may give it an advantage in terms of reduced material and manufacturing costs.

42 ENGINEERING↗

An Integrated Traction Drive with a High Speed Surface Permanent Magnet External Rotor Motor for Electric Vehicles

This work presents the detailed design of an outer rotor motor and integrated drive for passenger electric vehicles. The motor uses non-heavy rare earth permanent magnets and operates at a top speed of 20,000rpm. In-slot ceramic heat exchangers are utilized for the cooling of the windings. The external rotor configuration of the motor leaves a significant amount of space in the stator bore, which is leveraged for the integration of the power electronics. A high speed external rotor motor creates a number of mechanical, thermal and assembly challenges and this work presents detailed thermal, mechanical and rotordynamics analysis.

ADVANCED PROPULSION SYSTEMS↗

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↗

The Spectral Radiance of Indirectly Illuminated Surfaces in Regions of Permanent Shadow on the Moon

Regions of permanent shadow at the lunar poles have been suggested to host water ice and potentially other volatile compounds owing to their extremely low temperatures. Imaging in permanent shadow using indirect lighting from nearby topographic highs illuminated by the Sun has demonstrated the feasibility of optical remote sensing of permanent shadow surfaces, and a near-IR detection of water ice spectral features demonstrates the ability to collect usable spectroscopic data. The infrared emission of the lunar surface is largely in radiative equilibrium, so the temperature of surfaces in permanent shadow is driven by the intensity of the indirect illumination. This means that surfaces at very low temperatures, of high interest owing to their ability to trap and retain volatile compounds, will be the most challenging to measure. We provide estimates of indirect spectral radiance as a function of permanent shadow temperature from 400 nm to 14 μm using empirical data on permanent shadow temperature and broadband visible and near IR radiance, coupled with known reflectance properties of lunar materials. The relationships show there is ample radiance and photon radiance for reflectance imaging and spectroscopy from 400 nm to 8 μm at temperatures of regions of permanent shadow above 60K with appropriately designed instruments. Beyond 8 μm lunar spectral properties reduce the available radiance substantially, making reflectance observations challenging.

P. G. Lucey↗

Network Connectivity for Permanent, Transient, Independent, and Correlated Faults

This paper develops a method for the quantitative analysis of network connectivity in the presence of both permanent and transient faults. Even though transient noise is considered a common occurrence in networks, a survey of the literature reveals an emphasis on permanent faults. Transient faults introduce a time element into the analysis of network reliability. With permanent faults it is sufficient to consider the faults that have accumulated by the end of the operating period. With transient faults the arrival and recovery time must be included. The number and location of faults in the system is a dynamic variable. Transient faults also introduce system recovery into the analysis. The goal is the quantitative assessment of network connectivity in the presence of both permanent and transient faults. The approach is to construct a global model that includes all classes of faults: permanent, transient, independent, and correlated. A theorem is derived about this model that give distributions for (1) the number of fault occurrences, (2) the type of fault occurrence, (3) the time of the fault occurrences, and (4) the location of the fault occurrence. These results are applied to compare and contrast the connectivity of different network architectures in the presence of permanent, transient, independent, and correlated faults. The examples below use a Monte Carlo simulation, but the theorem mentioned above could be used to guide fault-injections in a laboratory.

White, Allan L.↗

Surface Reconstruction of a Challenging Region with Permanent Shadows on the Moon

As the Earth is orbiting the Sun, there is the region a sunlight can't be reached on the Moon, a satellite of the Earth. Usually, the permanent shadows are located near a pole area and the surface reconstruction in the permanent shadows region is challenging because of the lack of sunlight.In this research, the reconstruction method containing the permanent shadows is suggested. To apply this method, the time-varying shadow region and a permanently shadowed region are needed to be separated. In the time-varying shadow region, the pixel intensity of the image can be composed of the albedo and the reflectance model. Using the light source direction from ISIS3 of USGS, the shape of the region can be extracted from the reflectance model. Though this region is visible in the camera, the change of illumination is quite large in this region, it is hard to reconstruct the shape using stereo-photogrammetry or SfS. So, it is needed of collecting more surface normal information from several pixel level-aligned images. In this process, the albedo information can be initialized and enhanced easily from many images.In the middle of permanent shadows, the high-resolution DEM is generated by LOLA DEM. The LOLA DEM is generated by interpolation between measured data point strips, the actual scene of the permanent shadows. Using the sensor like DIVINER, the Imaginary scene generation via a trained network between the sunlight sensor and other kinds of a sensor is suggested.

Moon, Sunghyun↗

Exploration Helmet Permanent Anti-fog Study

For the current Extravehicular Mobility Unit (EMU) spacesuit, an astronaut applies an anti-fog solution to the interior of the helmet bubble before each EVA. However, the anti-fog solution has been reported to cause eye discomfort during at least seven EMU EVAs when the anti-fog solution contacted the crew member’s eyes. During STS-100, astronaut Chris Hadfield reported the eye irritation temporarily blinded him during his spacewalk. In addition, the wipe on anti-fog solution is a consumable that needs to be accounted for and a supply launched for missions. To solve this, the Exploration EMU (xEMU) pressure bubble investigated using a permanent anti-fog coating during Design Verification and Test (DVT) human in the loop (HITL) events. Chosen for previous use in Constellation Space Suit develop, HTAF-601, a water based permanent anti-fog solution, was tested. However, major issues have arisen with further HITL testing with the coating. Cleaning the helmet has been a challenge to avoid damaging the permanent anti-fog coating. NASA has completed a set of different methods for cleaning the anti-fog to try to document a preferred method. It was found isopropyl alcohol (IPA) cannot be used to clean the interior of the helmet because it will strip and delaminate the permanent anti-fog coating. Even with using a very gentle cleaning method of flushing with distilled or DI water and dabbing at facial oils, the permanent anti-fog starts to delaminate consistently after 50 hours manned pressurized time (MPT). Finally, the HTAF-601 coating is being discontinued by the vendor. Due to these issues, further investigation is being completed evaluating two solvent based anti-fog solutions: Exxene’s HCF-100 and FSI’s Visgard 106-94. Each coating will be evaluated on polycarbonate samples for application consistency, steam cycles (mimicking breath cycles), cleaning durability, haze, and light transmission. This study will determine if either coating is a viable option to pursue as a permanent anti-fog for spacesuit helmet applications.

spacesuit↗

Permanent magnets for ELM suppression in tokamaks: feasibility and operational compatibility

Permanent magnets can provide static magnetic fields without power supplies or feed lines, offering a simpler alternative to conventional electromagnets in tokamaks. This work examines permanent magnet arrays (PMAs) for edge localized mode (ELM) control in double-null (DN) configurations, where traditional RMP coils exhibit limited effectiveness. Linear plasma response calculations using IPEC assess high-field-side (HFS) permanent magnet placement, benchmarking performance against DIII-D low-field-side (LFS) internal coils (I-coils) while evaluating engineering constraints. Modeling results demonstrate that HFS permanent magnet configurations generate HFS plasma response amplitudes more than 5 times larger than conventional I-coil systems. While other resonant response metrics show comparable or reduced response relative to I-coils, the combination of conventional RMP systems and permanent magnets is expected to provide enhanced performance. Operational impact assessments of persistent magnetic fields, including sideband field effects and startup/ramp-up compatibility, reveal acceptable performance within established operational boundaries. This analysis establishes PMAs as a technically viable approach for DN ELM control with reductions in system complexity, motivating further experimental validation on existing tokamak facilities.

3D magnetic perturbation↗

NdFeB Permanent Magnet Uses, Projected Growth Rates and Nd Plus Dy Demands across End-Use Sectors through 2050: A Review

Rare earth element (REE) permanent magnets (NdFeB) are a critical element in a vast and growing number of industrial applications. In consumer electronics, a broad category encompassing computer, CD, and DVD hard drives, in addition to the ubiquitous cell phones, the nominal NdFeB magnet content may be small, but the global market share for this sector accounts for almost 30% of NdFeB demand, due to a large and continually increasing consumer base. It is estimated that wind turbines that primarily employ permanent magnets will add roughly 110 GW annually of on- and off-shore capability over the next few years. Electric vehicles (EVs) and E-bicycles (EBs) equipped with permanent magnet motors comprise the transportation contribution. Permanent magnet motors have garnered nearly 100% of the market share among EV manufacturers worldwide. Industrial, professional service, and personal robots, most using permanent magnets, are also included in the projected global need for rare earths, particularly Nd and Dy. The sector projects significant growth of approximately 10% across robotic categories. In this paper, we calculate the future demand for Nd and Dy through 2050 across these sectors using a compounded annual growth rate coupled with magnet weight and rare earth content. Uncertainties in the estimates, such as the true global production of Nd, a range of end-product scales and/or unit types in each sector, varied magnet compositions, and the variety of uses within a sector, are all considered.

Geochemistry & Geophysics↗

Permanent-File-Validation Utility Computer Program

Errors in files detected and corrected during operation. Permanent File Validation (PFVAL) utility computer program provides CDC CYBER NOS sites with mechanism to verify integrity of permanent file base. Locates and identifies permanent file errors in Mass Storage Table (MST) and Track Reservation Table (TRT), in permanent file catalog entries (PFC's) in permit sectors, and in disk sector linkage. All detected errors written to listing file and system and job day files. Program operates by reading system tables , catalog track, permit sectors, and disk linkage bytes to vaidate expected and actual file linkages. Used extensively to identify and locate errors in permanent files and enable online correction, reducing computer-system downtime.

Derry, Stephen D.↗

Toroidal-Core Microinductors Biased by Permanent Magnets

The designs of microscopic toroidal-core inductors in integrated circuits of DC-to-DC voltage converters would be modified, according to a proposal, by filling the gaps in the cores with permanent magnets that would apply bias fluxes (see figure). The magnitudes and polarities of the bias fluxes would be tailored to counteract the DC fluxes generated by the DC components of the currents in the inductor windings, such that it would be possible to either reduce the sizes of the cores or increase the AC components of the currents in the cores without incurring adverse effects. Reducing the sizes of the cores could save significant amounts of space on integrated circuits because relative to other integrated-circuit components, microinductors occupy large areas - of the order of a square millimeter each. An important consideration in the design of such an inductor is preventing magnetic saturation of the core at current levels up to the maximum anticipated operating current. The requirement to prevent saturation, as well as other requirements and constraints upon the design of the core are expressed by several equations based on the traditional magnetic-circuit approximation. The equations involve the core and gap dimensions and the magnetic-property parameters of the core and magnet materials. The equations show that, other things remaining equal, as the maximum current is increased, one must increase the size of the core to prevent the flux density from rising to the saturation level. By using a permanent bias flux to oppose the flux generated by the DC component of the current, one would reduce the net DC component of flux in the core, making it possible to reduce the core size needed to prevent the total flux density (sum of DC and AC components) from rising to the saturation level. Alternatively, one could take advantage of the reduction of the net DC component of flux by increasing the allowable AC component of flux and the corresponding AC component of current. In either case, permanent-magnet material and the slant (if any) and thickness of the gap must be chosen according to the equations to obtain the required bias flux. In modifying the design of the inductor, one must ensure that the inductance is not altered. The simplest way to preserve the original value of inductance would be to leave the gap dimensions unchanged and fill the gap with a permanent- magnet material that, fortuitously, would produce just the required bias flux. A more generally applicable alternative would be to partly fill either the original gap or a slightly enlarged gap with a suitable permanent-magnet material (thereby leaving a small residual gap) so that the reluctance of the resulting magnetic circuit would yield the desired inductance.

Lieneweg, Udo↗

Stability of the Early Mars Atmosphere to Collapse into Permanent Polarcaps

The presence of a permanent CO2 polar ice cap on Mars has important consequences for the planet's climate system. The heat balance of such a cap, which is determined mainly by atmospheric heat transport, and the downward solar in infrared radiative fluxes, determines its surface temperature, which through the vapor pressure relation sets the mean annual surface pressure. On Mars today, for example, the south residual CO2 cap is present year-round with a mean annual temperature of approximately 145 K which corresponds to a mean annual CO2 vapor pressure of approximately 600 Pa. On early Mars, permanent polar caps are also possible especially since the sun was less luminous 3.5-4.0 Gya. Thus, the existence of permanent polar caps on early Mars is central to understanding the nature of the planets climate system in those ancient times and whether or not the atmosphere might have been capable of sustaining conditions suitable for liquid water flowing over the surface as is indicated in the geological record. Forget et al [1] showed that for present orbital properties atmospheric collapse into permanent polar caps could only be prevented for surface pressures roughly between 500 - 3000 hPa. Though follow-on studies confirm and extend the Forget et al. results [2], the full sensitivity of this "window" of stability has not been explored. There are many factors to consider such the albedo of the caps, dust content of the atmosphere, and the presence of water ice clouds. However, we begin our exploration of the stability of the early Martian atmosphere by focusing on the role of CO2 ice clouds. In some preliminary simulations with the Ames Mars General Circulation Model (GCM) we found that atmospheric collapse depends on assumptions regarding the fate of CO2 ice clouds. If, for example, we assume the clouds immediately fall to the surface, then in some cases collapse is favored. On the other hand if the clouds are allowed to fall and evaporate, collapse can be averted. This implies that CO2 ice cloud microphysics is important to the overall stability of the atmosphere. Though the Ames GCM has a sophisticated CO2 cloud microphysics package that includes nucleation, growth, and sedimentation (see accompanying poster by Kahre et al. [3]), we have implemented a simpler scheme based on the Forget et al. [1] approach to CO2 ice clouds. Our goal is to reproduce and expand their study. The key parameter in this approach is the concentration and vertical distribution of cloud condensation nuclei (CCN), i.e., dust particles. Fewer CCN lead to larger particles which fall faster, while higher CCN concentrations lead to smaller particles and thicker clouds that remain suspended for longer periods of time. We plan to explore the stability of the atmosphere to CCN concentrations and distributions and then assess the capability of thick early atmospheres to loft and distribute dust particles (CCN) around the planet. Thus, our work will shed light on the nature of the coupling between the dust and CO2 cycles and the implications it has for the early Mars climate system.

ice cap↗

Design and instrumentation for permanent magnet samples exposed to a radiation environment

This work is part of a larger program to study the effects of radiation on permanent magnets in an accelerator environment. In order to be sure that the permanent magnet samples are accurately placed, measured, and catalogued we have developed a system of sample racks, holders and measuring apparatuses. We have combined these holders and measurement racks with electronics to allow a single computer to catalogue the position and intensity of the magnet measurements. We outline the design of the apparatus, the collection software, and the methodology we will use to collect the data.

Accelerator Physics↗