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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 OSTI2023

Comparative Life Cycle Assessment of Injection Molded and Big Area Additive Manufactured NdFeB Bonded Permanent Magnets

Permanent magnets are expected to play a crucial role in the realization of the clean economy. In particular, the neodymium-iron-boron (Nd2Fe14B or NdFeB) magnets, which have the highest energy density among rare earth permanent magnets, are needed for building more efficient windmill generators, electric vehicle motors, etc. Currently, near-net shape magnets can be either made through sintering and compression molding with extensive post machining or directly through injection molding. However, injection molding has a loading volume fraction limitation of 0.65 for nylon binders. A novel method of manufacturing bonded permanent magnets with loading fraction greater than 0.65 has been demonstrated using Big Area Additive Manufacturing (BAAM) printers. As energy density is directly proportional to the square of the magnet loading fraction, magnets produced using BAAM printers require less volume and magnetic material compared to that of injection molded magnets on average. A comparative LCA shows that this difference in magnetic powder consumption nearly constitutes the difference in the environmental impact categories. Even after assuming recycled magnetic input, the BAAM magnets perform better environmentally than injection molded magnets, especially in the ozone depletion category. Since BAAM printers can accommodate even higher loading fractions, at scale, BAAM printers possibly can bring about a significant decrease in rare earth mineral consumption and environmental emissions. So furthermore, single screw extrusion enables BAAM printers to have high print speeds and allow them to be economically competitive against injection molding. Therefore, BAAM printed magnets show promise in transitioning towards the clean economy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

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↗
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 OSTI2023

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↗
DOE OSTI2024

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↗
DOE OSTI2023

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↗
DOE OSTI2025

Focusing of relativistic electron beams with permanent magnetic solenoid

Achieving strong focusing of MeV electron beams is a critical requirement for advanced beam applications such as compact laboratory x-ray sources, high gradient accelerators, and ultrafast electron scattering instrumentation. To address these needs, a compact radially magnetized permanent magnetic solenoid (PMS) has been designed, fabricated, and tested. The solenoid provides a compact and inexpensive solution for delivering high axial magnetic fields (1 T) to focus MeV electron beams. Field characterization of the solenoid demonstrates good agreement with analytical models, validating the PMS design. The electron beam test employs a high-brightness photoinjector to study the focusing properties of the PMS. The results indicate a focal length of less than 10 cm and a significant reduction in beam size with small spherical aberrations. Two application cases are evaluated: angular magnification in ultrafast electron diffraction setups and strong focusing for Compton scattering or other microfocus uses.

Electron diffraction↗
DOE OSTI2026

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↗
DOE OSTI2025

Universal Electronic‐Structure Relationship Governing Intrinsic Magnetic Properties in Permanent Magnets

An electronic-structure-centered perspective is presented on permanent-magnet (PM) design, highlighting two key levers, that is, saturation magnetization (M s ), governed by 3d-band filling and exchange physics, and magnetocrystalline anisotropy energy (MAE), arising from spin-orbit coupling (SOC) on anisotropic orbital populations. Reviewing current practices, including DFT-based MAE/J ij extraction, atomistic-spin and micromagnetic modeling, and high-throughput machine learning (ML) pipelines, three bottlenecks limiting predictive discovery is identified that is i) electronic-structure accuracy for small MAE (sensitive to functional choice, Hubbard U, and many-body effects), ii) finite-temperature and kinetic realism (phonon/magnon renormalization, ordering kinetics), and iii) descriptor and multiscale decoupling (lack of SOC-weighted and orbital-resolved fingerprints). Deep dives into the electronic-structure of Nd─Fe─B and Fe─N show how these fingerprints govern magnetic performance, motivating DFT- and quantum-mechanics-based descriptors for discovery. Unbiased, structure-driven exploration, coupled with high-throughput simulations, ML, generative AI, and reasoning models, accelerates candidate identification and propagates insights across scales. Addressing supply-chain risks, on future needs of designing “critical-element-free” magnets with tailored microstructure and high energy products is emphasized. By integrating electronic fingerprints, AI reasoning, and multiscale modeling, a practical roadmap is provided for rare-earth-lean or rare-earth free, high-performance, sustainable PMs.

Singh, Prashant [Ames Laboratory, and Iowa State U↗
DOE OSTI2023

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↗
DOE OSTI2026

A solid-state extrusion pathway extensible to upcycling aluminum scrap and end-of-life permanent magnets into ductile Al-6061/SmCo 5 structural magnetic composites

Permanent magnets offer strong potential for multifunctional structural components, but their inherent brittleness limits direct integration. Here, SolidStir® Extrusion (SSE) is used to embed SmCo5 powder into AA6061 in the solid state, and the resulting microstructure, interfacial chemistry, mechanical properties, and magnetic response are systematically characterized. SSE fragments the initial SmCo 5 powder into predominantly fine particles dispersed within an ultrafine Al matrix, with a volume fraction of ∼ 4–6 % in this proof-of-concept study. Interfacial reactions form a continuous Al–Co reaction layer, with local atomic-resolution indexing consistent with Al 13 Co 4 , together with Sm–Si-rich reaction products, while the matrix contains Sm–Co–Si-rich precipitates and Mg 2 Si, producing features from nanometers to micrometers. Compared with an Al extrudate, this architecture increases yield strength by ∼ 42 % and tensile strength by ∼ 31 %, while preserving uniform elongation, and it sustains work hardening in compression from 150 to 400 °C. The composite retained hard-magnetic behavior, with axial magnetization of 12.7 A·m 2 kg −1 at 6 T and intrinsic coercivity of 9.6 kOe. These findings demonstrate that SSE can produce Al-based load-bearing magnetic composites while preserving useful SmCo5 functionality.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Permanent Magnets Featuring Heavy Main Group Elements for Magnetic Anisotropy

Permanent magnets are the functional component of electric motors and generators found in numerous renewable energy applications. To improve energy conversion in such applications, we require fundamentally new magnets that generate higher magnetic flux per volume while retaining the properties conferred by rare-earth elements incorporated into current technologies. We hypothesize that by engendering a covalent interaction between two elements, we can access a new regime of magnetic materials where the two components of a magnetic moment—spin and orbital angular momentum—come from two separate atoms to form a complete magnetic moment. Our previous research utilized high-pressure conditions to discover two new candidate materials ideal for assessing this hypothesis. The first material, FeBi 2 , enables the study of an unprecedented solid state metal-metal bonding interaction. The second, MnBi 2 represents the second member of the promising Mn–Bi family known for its magnetic properties. Importantly, MnBi 2 is isostructural to FeBi 2 . Together these chemically simple but magnetically rich materials provide an elegant platform for elucidating fundamental design principals of magnetic anisotropy while inspiring the synthesis of new magnetic materials. More generally, solid-state chemistry remains a synthetic black box. To fully harness the potential of such new materials, it is vital to create a window into both the structure and the properties of our high-pressure materials. One missing area of importance to energy science is high-pressure magnetometry. To this end, we assessed the magnetic structure of these materials through two objectives: (1) we performed magnetometry measurements at high-pressures, including performing high-pressure X-ray Magnetic Circular Dichroism (XMCD) experiments on these materials that are only synthesized at high-pressure and cannot be recovered to ambient conditions and (2) we targeted the recovery of these materials using dynamic compression approaches, starting with laser shock techniques. Future directions include expanding our focus to ternary phase space, employing high-throughput computational approaches to direct our search for magnetic materials across the Periodic Table. This award was originated at Northwestern, and reopened as a new grant at MIT. This is the close out for Northwestern.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Rotor Magnet Fault Analysis in Permanent Magnet AC Machines Under Load Conditions - All Electric Transportation Systems

This paper studies the performance of a Permanent Magnet (PM) alternating-current (AC) machine when subjected to faults under load conditions. The effect of varying load torques, and unbalances are found to be potential causes of rotor faults, inducing physical magnet defects or broken rotor-PMs. The consequent and immediate impact on the machine quantities is observed through anomalous change in torque-speed characteristics and other vital signatures such as machine back-EMF/flux and motor current signatures (MCS). The present research study develops and illustrates a method to diagnose physical magnet defects (fault) in PMAC machines by estimating the machine torque/back-EMF constant, Ke. The constant Ke is a measure of magnet strength exhibiting the health of rotor PMs, indicative of faults. Advanced research studies and investigations are carried out to establish motor approximations and signature-based analysis as significant viable tools for diagnosing machine faults even under load conditions.

alternating current↗
DOE OSTI2025

MnBi 2 Is a Permanent Magnet

Creating and understanding new permanent magnets requires an understanding of the impact of orbital angular momentum on coercivity. A simple approach to interrogating this relationship is by incorporating high Z (where Z is the atomic number) elements into binary compounds to maximize spin–orbit coupling. The Mn–Bi system is an appealing platform for these studies since it contains MnBi, a permanent magnet with a large coercive field. We previously identified a new compound in the Mn–Bi system, MnBi 2 , but could not elucidate its magnetic properties ex situ due to its decomposition upon decompression. Here, we harnessed synchrotron X-ray magnetic circular dichroism to probe the magnetism of MnBi 2 at high pressure within a diamond anvil cell. Our results indicate that MnBi 2 exhibits ferromagnetic hysteresis at both 10 K and room temperature. Through calculations and experiments, we show that orbital angular momentum and spin–orbit coupling from Bi impart magnetic anisotropy in MnBi 2 . Comparing the Mn–Bi family of compounds, we consider the Bi p and d orbitals to explain the differences in magnetic behavior within the system. Collectively, these results validate leveraging high-Z elements in the synthesis of new hard permanent magnets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

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↗
DOE OSTI2026

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↗
DOE OSTI2023

A Review of Axial Flux Permanent Magnet Machine Technology

Axial flux permanent magnet machines (AFPM) are popular for applications that benefit from high torque density and an axially compact form factor, such as in-wheel traction drives. Although the radial flux permanent magnet machine (RFPM) and the AFPM work based on the same underlying principle, the differences in their geometry introduce complexities in analysis of the AFPM. In this paper, the different AFPM design variants, their sizing approaches, computationally efficient design optimization techniques, and manufacturing techniques reported in literature are reviewed. In addition to classical AFPM machines, emerging variants and research opportunities with potential to push the boundaries of electric machine technology are reviewed. Furthermore, these include bearingless AFPMs, magnetically geared AFPMs, and combined radial-axial flux machines.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

High-performance permanent-magnet materials based on CeFe 12

We perform first-principles calculations on the Mo/Zr-alloyed ThMn 12 -structure prototype CeFe 12 to explore its electronic and magnetic properties and potential for permanent magnet applications. A recent experiment has shown that the Mo/Zr-alloyed CeFe 12 phase with the symmetry 𝐼⁢4/𝑚⁢𝑚⁢𝑚 can be stabilized in bulk. It encourages an investigation into the intrinsic magnetic characteristics of the base structure CeFe 12 and the effect of transition metal alloying in it. Our calculations reveal that the base structure prototype CeFe 12 in its tetragonal phase exhibits uniaxial magnetic anisotropy with a magnetic anisotropy energy (𝐾 1 ) ∼ 1 MJ/m −3 and a substantial magnetic moment of ∼ 1.8T, showing its promise as a permanent magnet. The introduction of the stabilizing transition metals Zr, Mo, and W reduces these values but still keeps the materials very promising. Notably, when 50% of Ce is substituted by Sm in Mo-alloyed CeFe 12 , the 𝐾 1 is significantly enhanced, accompanied by a fairly decent magnetic moment of ∼ 1.2T. These findings establish this alloy as a strong candidate for high-performance permanent magnet applications. In conclusion, this study emphasizes the importance of strategic element substitution and site selection in transition metal-alloyed CeFe 12 to achieve both structural stability and remarkable magnetic properties.

Density of states↗