Additive manufacturing of soft magnets for electrical machines—a review
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36 MATERIALS SCIENCE↗
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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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Modeling and Characterization of the Magnetocaloric Effect in Ni2MnGa Materials
Magnetic shape memory alloys have great promise as magneto-caloric effect refrigerant materials due to their combined magnetic and structural transitions. Computational and experimental research is reported on the Ni2MnGa material system. The magnetic states of this system are explored using the Wang-Landau statistical approach in conjunction with the Locally Self-consistent Multiple-Scattering method. The effects of alloying agents on the transition temperatures of the Ni2MnGa alloy are investigated using differential scanning calorimetry and superconducting quantum interference device. Experiments are performed at the Spallation Neutron Source at Oak Ridge National Laboratory to observe the structural and magnetic phase transformations.
magneto caloric↗
The Effects of Ferromagnetic Disks on AC Losses in HTS Pancake Coils with Nonmagnetic and Magnetic Substrates
Performance improvement of high-temperature superconducting (HTS) pancake coil is of paramount importance for its application in electrical facilities. In this paper, the utilization of ferromagnetic disks including weak magnetic material and strong magnetic material is investigated through numerical simulations for the aim of reducing the AC loss. Both the nonmagnetic and magnetic substrates are considered for the rare-earth-barium-copper-oxide coated conductor tapes wounded into the pancake coil. In order to analyze the influences of ferromagnetic disks on the maximum allowable currents and AC losses of nonmagnetic substrate-based coil and magnetic substrate-based coil, a self-consistent model based on the A-formulation is adopted to calculate the critical current and a 2D axisymmetric model built on the H-formulations is established to calculate the AC loss. According to the simulation results, it is found that ferromagnetic disks especially the strong magnetic disk are slightly detrimental to the critical currents of the pancake coils. Nevertheless, the presence of large background field weakens the effects of ferromagnetic disks. The simulation results also indicate that strong magnetic disks achieve about 50% reduction of the AC loss in the nonmagnetic substrate-based coil, and the AC loss of the magnetic substrate-based coil can be increased or reduced with strong magnetic disks depending on the applied current amplitude. The utilization of strong magnetic disks leads to the enhancement of the AC loss in the magnetic substrate-based coil at lower current and to the reduction of it at larger current.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Model for temperature-dependent magnetization of nanocrystalline materials
A magnetization model of nanocrystalline materials incorporating intragrain anisotropies, intergrain interactions, and texture effects has been extended to include the thermal fluctuations. The method relies on the stochastic Landau–Lifshitz–Gilbert theory of magnetization dynamics and permits to study the magnetic properties of nanocrystalline materials at arbitrary temperature below the Currie temperature. The model has been used to determine the intergrain exchange constant and grain boundary anisotropy constant of nanocrystalline Ni at 100 K and 298 K. It is found that the thermal fluctuations suppress the strength of the intergrain exchange coupling and also reduce the grain boundary anisotropy. In comparison with its value at 2 K, the interparticle exchange constant decreases by 16% and 42% and the grain boundary anisotropy constant decreases by 28% and 40% at 100 K and 298 K, respectively. An application of the model to study the grain size-dependent magnetization indicates that when the thermal activation energy is comparable to the free energy of grains, the decrease in the grain size leads to the decrease in the magnetic permeability and saturation magnetization. The mechanism by which the grain size influences the magnetic properties of nc–Ni is discussed.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Magnetic mesoporous materials for removal of environmental wastes
We have synthesized two different magnetic mesoporous materials that can be easily separated from aqueous solutions by applying a magnetic field. Synthesized magnetic mesoporous materials, Mag-SBA-15 (magnetic ordered mesoporous silica) and Mag-OMC (magnetic ordered mesoporous carbon), have a high loading capacity of contaminants due to high surface area of the supports and high magnetic activity due to the embedded iron oxide particles. Application of surface-modified Mag-SBA-15 was investigated for the collection of mercury from water. The mercury adsorption using Mag-SBA-15 was rapid during the initial contact time and reached a steady-state condition, with an uptake of approximately 97% after 7 hours. Application of Mag-OMC for collection of organics from water, using fluorescein as an easily trackable model analyte, was explored. The fluorescein was absorbed into Mag-OMC within minutes and the fluorescent intensity of solution was completely disappeared after an hour. In another application, Mag-SBA-15 was used as a host of tyrosinase, and employed as recyclable catalytic scaffolds for tyrosinase-catalyzed biodegradation of catechol. Tyrosinase aggregates in Mag-SBA-15, prepared in a two step process of tyrosinase adsorption and crosslinking, could be used repeatedly for catechol degradation with no serious loss of enzyme activity. Considering these results of cleaning up water from toxic inorganic, organic and biochemical contaminants, magnetic mesoporous materials have a great potential to be employed for the removal of environmental contaminants and potentially for the application in large-scale wastewater treatment plants.
36 MATERIALS SCIENCE↗
To Substitute Rather Than Intercalate: Chimie douce Approach to Induce Ferromagnetism in Metastable Pt 0.8 M 0.2 Se 2 ( M = Cr, Co, Ni)
Two-dimensional (2D) magnetic materials with exotic magnetic properties have garnered significant interest due to their potential applications in spintronics and data storage technologies. However, the limited availability of intrinsic 2D magnetic materials has driven efforts to induce and manipulate magnetism in otherwise nonmagnetic 2D systems through approaches such as chemical intercalation, defect engineering, and substitutional doping. Herein, we present a facile, chimie douce method for incorporating 3d transition metals (Cr, Co, and Ni) into the nonmagnetic PtSe 2 sublattice. This synthetic approach enables control over layer thickness of Pt 1–x M x Se 2 (M = Cr, Co, Ni) nanosheets by varying the M identity and annealing conditions. Comprehensive scattering and spectroscopic characterizations confirm the successful and homogeneous substitution of M atoms at the Pt site, rather than intercalation, and reveal a strong correlation between nanosheet thickness and the identity of the substituting metal. High-temperature annealing of the nanosheets promotes an irreversible transformation toward the bulk phase, allowing for detailed characterization of structural and magnetic properties. A case study of Pt 0.8 Cr 0.2 Se 2 reveals that nanosheet thickness plays a critical role in modulating local magnetic interactions. While Cr atoms in the as-synthesized few-layers-thick nanosheets exhibit predominantly short-range antiferromagnetic interactions, the emergence of short-range ferromagnetic exchange is revealed in the bulk material. Detailed ac susceptibility and remanent magnetization measurements further demonstrate that bulk Pt 0.8 Cr 0.2 Se 2 adopts a frustrated magnetic ground state with clear signatures of ferromagnetic cluster-glass behavior. The systematic investigation presented herein establishes a clear and robust protocol for the synthesis and in-depth characterization of 2D transition-metal-substituted PtSe2 materials with varying layer thickness and paves a path toward their realization in spintronic and magnetic device applications.
crystallinity↗
Development of an x-ray diffraction camera used in magnetic fields up to 10 T
A high-field x-ray diffraction (HF-XRD) camera was developed to observe structural changes of magnetic materials in magnetic fields up to 10 T. The instrument mainly consists of a Debye-Scherrer-type camera with a diameter of 80.1 mm, a 10-T cryocooled superconducting magnet with a 100-mm room-temperature bore, an x-ray source, a power supply, and a chiller for the x-ray source. An x-ray detector (image plate) in the HF-XRD camera can be taken out and inserted into the magnet without changing the sample position. The performance of the instrument was tested by measuring the HF-XRD for silicon and ferromagnetic MnBi powders. A change of x-ray diffraction pattern was observed due to the magnetic orientation of MnBi, showing that the instrument is useful for studying field-induced orientation processes and structural properties of field-controlled materials.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Final Scientific/Technical Report for DOE/EERE project Advanced Magnetic Refrigerant Materials
A team led by GE Global Research developed new magnetic refrigerant materials needed to enhance the commercialization potential of residential appliances such as refrigerators and air conditioners based on the magnetocaloric effect (a nonvapor compression cooling cycle). The new magnetic refrigerant materials have potentially better performance at lower cost than existing materials, increasing technology readiness level. The performance target of the new magnetocaloric material was to reduce the magnetic field needed to achieve 4 °C adiabatic temperature change (ΔT adiabatic ) from 1.5 Tesla to 0.75 Tesla. Such a reduction in field minimizes the cost of the magnet assembly needed for a magnetic refrigerator. Such a reduction in magnet assembly cost is crucial to achieving commercialization of magnetic refrigerator technology. This project was organized as an iterative alloy development effort with a parallel material modeling task being performed at George Washington University. Four families of novel magnetocaloric alloys were identified, screened, and assessed for their performance potential in a magnetic refrigeration cycle. Compositions from three of the alloy families were manufactured into regenerator components. At the beginning of the project a previously studied magnetocaloric alloy was selected for manufacturing into the first regenerator component. Each of the regenerators was tested in magnetic refrigerator prototypes at a subcontractor at at GE Appliances. The property targets for operating temperature range, operating temperature control, magnetic field sensitivity, and corrosion resistance were met. The targets for adiabatic temperature change (ΔT adiabatic ) and thermal hysteresis were not met. The high thermal hysteresis also prevented the regenerator components from displaying measurable cooling power when tested in prototype magnetic refrigerators. Magnetic refrigerant alloy compositions that were predicted to have low hysteresis were not attainable with conventional alloy processing methods. Preliminary experiments with rapid solidification methods showed a path towards attaining low hysteresis compositions should this alloy development effort be continued.
36 MATERIALS SCIENCE↗
Electric Motors for Non-Cryogenic Hybrid Electric and Turboelectric Propulsion
NASA Glenn Research Center is investigating hybrid electric and turboelectric propulsion concepts for future aircraft to reduce fuel burn, emissions, and noise. Systems studies show that the weight and efficiency of the electric system components need to be improved for this concept to be feasible. However, advances in motor component materials such as soft magnetic materials, hard magnetic materials, conductors, thermal insulation, and structural materials are expected in the coming years, and should improve motor performance. This study investigates several motor types for a one megawatt application, and projects the motor performance benefits of new component materials that might be available in the coming decades.
Hybrid propulsion↗
Electric Motor Considerations for Non-Cryogenic Hybrid Electric and Turboelectric Propulsion
NASA Glenn Research Center is investigating hybrid electric and turboelectric propulsion concepts for future aircraft to reduce fuel burn, emissions, and noise. Systems studies show that the weight and efficiency of the electric system components need to be improved for this concept to be feasible. However, advances in motor component materials such as soft magnetic materials, hard magnetic materials, conductors, thermal insulation, and structural materials are expected in the coming years, and should improve motor performance. This study investigates several motor types for a one megawatt application, and projects the motor performance benefits of new component materials that might be available in the coming decades.
Hybrid propulsion↗
Electric Drive Technologies Research: Bottom-Up Soft Magnetic Composites (FY2022 Annual Progress Report)
In order to meet 2025 goals for enhanced peak power (100 kW), specific power (50 kW/L), and reduced cost (3.3 $\$$/kW) in a motor that can operate at ≥ 20,000 rpm, improved soft magnetic materials must be developed. Better performing soft magnetic materials will also enable rare earth free electric motors. In fact, replacement of permanent magnets with soft magnetic materials was highlighted in the Electrical and Electronics Technical Team (EETT) Roadmap as a R&D pathway for meeting 2025 targets. Eddy current losses in conventional soft magnetic materials, such as silicon steel, begin to significantly impact motor efficiency as rotational speed increases. Soft magnetic composites (SMCs), which combine magnetic particles with an insulating matrix to boost electrical resistivity (ρ) and decrease eddy current losses, even at higher operating frequencies (or rotational speeds), are an attractive solution. Today, SMCs are being fabricated with values of ρ ranging between 10 -3 to 10 -1 μohm∙m, which is significantly higher than 3% silicon steel (~0.05 μohm∙m). The isotropic nature of SMCs is ideally suited for motors with 3D flux paths, such as axial flux motors. Additionally, the manufacturing cost of SMCs is low and they are highly amenable to advanced manufacturing and net-shaping into complex geometries, which further reduces manufacturing costs. There is still significant room for advancement in SMCs, and therefore additional improvements in electrical machine performance. For example, despite the inclusion of a non-magnetic insulating material, the electrical resistivities of SMCs are still far below that of soft ferrites (10 – 10 8 μohm∙m).
33 ADVANCED PROPULSION SYSTEMS↗
The reaction mechanism of formation of chemically synthesized Nd{sub 2}Fe{sub 14}B hard magnetic nanoparticles
Nd{sub 2}Fe{sub 14}B based magnetic materials exhibit excellent magnetic properties and are widely used in many engineering applications. However, chemical synthesis of this compound is challenging. In this work, the formation mechanism of chemically synthesized Nd{sub 2}Fe{sub 14}B magnetic nanoparticles was studied. Nd, Fe and B precursors were converted to Nd-Fe-B oxide by the sol-gel method, reduction of these oxides by CaH{sub 2} resulted in Nd{sub 2}Fe{sub 14}B nanoparticles. Nd{sub 2}Fe{sub 14}B phase formation resulted from two competing reactions: (a) Nd{sub 2}Fe{sub 14}B phase formation by direct combination of NdH{sub 2}, Fe and B, (b) Nd{sub 2}Fe{sub 17} phase formation from NdH{sub 2} and Fe, followed by Nd{sub 2}Fe{sub 14}B phase formation by the reaction of Nd{sub 2}Fe{sub 17} and B. Addition of boron to Nd-Fe-B oxide during reduction resulted in improved magnetic properties. The activation energy for Nd{sub 2}Fe{sub 14}B phase formation was found to be 365 kJ mol{sup -1}. The optimum heat treatment temperature and time for Nd{sub 2}Fe{sub 14}B phase formation were found to be 800 Degree-Sign C and 90 min, respectively. - Graphical abstract: The kinetics, reaction mechanism and morphology of Nd{sub 2}Fe{sub 14}B magnetic nanoparticles synthesized by sol-gel followed by reduction-diffusion at 800 Degree-Sign C. Highlights: Black-Right-Pointing-Pointer The formation mechanism of Nd{sub 2}Fe{sub 14}B magnetic nanoparticles was studied. Black-Right-Pointing-Pointer Nd{sub 2}Fe{sub 14}B phase formation occurs by two parallel competing reactions. Black-Right-Pointing-Pointer Reaction of NdH{sub 2}, Fe and B resulted in Nd{sub 2}Fe{sub 14}B phase formation. Black-Right-Pointing-Pointer Nd{sub 2}Fe{sub 14}B phase can also be formed by the reaction of Nd{sub 2}Fe{sub 17} and B. Black-Right-Pointing-Pointer Maximum wt% of Nd{sub 2}Fe{sub 14}B phase was obtained at 800 Degree-Sign C and 90 min annealing.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Bottom-Up Soft Magnetic Composites
In order to meet 2025 goals for enhanced peak power (100 kW), specific power (50 kW/L), and reduced cost (3.3 $/kW) in a motor that can operate at ≥ 20,000 rpm, improved soft magnetic materials must be developed. Better performing soft magnetic materials will also enable electric motors without rare earth elements. In fact, replacement of permanent magnets with soft magnetic materials was highlighted in the Electrical and Electronics Technical Team (EETT) Roadmap as a R&D pathway for meeting 2025 targets. Eddy current losses in conventional soft magnetic materials, such as silicon steel, begin to significantly impact motor efficiency as rotational speed is increased. Soft magnetic composites (SMCs), which combine magnetic particles with an insulating matrix to boost electrical resistivity (ρ) and decrease eddy current losses, even at higher operating frequencies (or rotational speeds), are an attractive solution. Today, SMCs are being fabricated with values of ρ ranging between 10 -3 to 10 -1 μohm∙m, which is significantly higher than 3% silicon steel (~0.5 μohm∙m). The isotropic nature of SMCs is ideally suited for motors with 3D flux paths, such as axial flux motors. Additionally, the manufacturing cost of SMCs is low and they are highly amenable to advanced manufacturing and net-shaping into complex geometries, which further reduces manufacturing costs. There is still significant room for advancement in SMCs, and therefore additional improvements in electrical machine performance. For example, despite the inclusion of a non-magnetic insulating material, the electrical resistivities of SMCs are still far below that of soft ferrites (10 – 10 8 μohm∙m).
36 MATERIALS SCIENCE↗
Self-Cooling Multiferroic Magnetic Devices
Increasing switching frequency reduces magnetic volume, but conventional ferrites, used from tens to hundreds of kilohertz, cannot sustain the temperature and frequency ranges demanded by current and emerging wide bandgap and ultrawide bandgap devices. Here, this work presents a novel magnetic material architecture combining nanocrystalline magnetic material and multiferroic layers for megahertz power conversion. The high saturation flux density of nanocrystalline alloys supports miniaturization but is traditionally constrained by excessive losses above 10 kHz. A revolutionary multiferroic material with solid-state cooling via caloric materials is defined that will enable the next generation of magnetic devices for wide-bandgap-integrated designs. This letter highlights the fundamental physics behind this capability alongside early development of a finite element analysis for the multiferroic-based magnetic device using ANSYS, showing that the core achieves more uniform thermal distribution and reduces peak temperature by 9 ° C compared to conventional ferrites.
Soft magnetic materials↗
High-throughput search for magnetic topological materials using spin-orbit spillage, machine learning, and experiments
Magnetic topological insulators and semi-metals have a variety of properties that make them attractive for applications including spintronics and quantum computation. Here, we use systematic high-throughput density functional theory calculations to identify magnetic topological materials from the ≈ 40000 three-dimensional materials in the JARVIS-DFT database. First, we screen materials with net magnetic moment > 0.5 μB and spin-orbit spillage > 0.25, resulting in 25 insulating and 564 metallic candidates. The spillage acts as a signature of spin-orbit induced band-inversion. Then, we carry out calculations of Wannier charge centers, Chern numbers, anomalous Hall conductivities, surface bandstructures, and Fermi-surfaces to determine interesting topological characteristics of the screened compounds. We also train machine learning models for predicting the spillage, bandgaps, and magnetic moments of new compounds, to further accelerate the screening process. We experimentally synthesize and characterize a few candidate materials to support our theoretical predictions.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Recent progress of magnetocaloric effect and magnetic refrigerant materials of Mn compounds (invited)
Magnetocaloric and related properties of Ru and Ni substituted (MnFe){sub 2}(PSi) are presented. It is found that Ru and Ni are effective doping elements to reduce the thermal hysteresis of (MnFe){sub 2}(PSi). The origin of the thermal hysteresis is discussed on the basis of a thermodynamic model. It is shown that the elastic energy is responsible for the thermal hysteresis. We also show recent developments of the production process of Mn compounds in an industrial scale.
36 MATERIALS SCIENCE↗
K 2 CoS 2 : A two-dimensional in-plane antiferromagnetic insulator
Recent discovery of two-dimensional (2D) magnetic materials has brought magnetism to the flatland and opened up exciting opportunities for the exploration of fundamental physics as well as novel device applications. Here, we predict a thermodynamically stable 2D magnetic material, ${\mathrm{K}}_{2}{\mathrm{CoS}}_{2}$, which retains its in-plane bulk antiferromagnetic (AFM) order down to the monolayer and bilayer limits. Magnetic moments $(2.5{{\mu}}_{B}/\mathrm{Co})$ are found to form a quasi-one-dimensional antiferromagnetically ordered chain of Co atoms. The nonmagnetic electronic spectrum of the monolayer film is found to host flatbands and van Hove singularities, which play a key role in stabilizing the magnetic ground state. Based on classical Monte Carlo simulations, we estimate the Neel temperature for the AFM monolayer to be ${\approx}15\mathrm{K}$. Our study demonstrates that ${\mathrm{K}}_{2}{\mathrm{CoS}}_{2}$ hosts a robust AFM state which persists from the monolayer limit to the bulk material.
2-dimensional systems↗
The development and the results of a sputtering procedure for alfesil-yielding thin magnetic coating materials Final report
Sputtering procedure for yielding Alfesil thin magnetic coating materials - mechanical, electric, and magnetic properties of Alfesil
ELECTRIC PROPERTY↗