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All sources NASA NTRS DOE OSTI

NASA NTRS2001

Accurate Time-Dependent Traveling-Wave Tube Model Developed for Computational Bit-Error-Rate Testing

The phenomenal growth of the satellite communications industry has created a large demand for traveling-wave tubes (TWT's) operating with unprecedented specifications requiring the design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies on computational modeling. However, the TWT industry's computational modeling capabilities need to be improved because there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This limits the analysis and design of novel devices or TWT's with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. To address these concerns, a fully three-dimensional, time-dependent, helical TWT interaction model was developed using the electromagnetic particle-in-cell code MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm). The model includes a short section of helical slow-wave circuit with excitation fed by radiofrequency input/output couplers, and an electron beam contained by periodic permanent magnet focusing. A cutaway view of several turns of the three-dimensional helical slow-wave circuit with input/output couplers is shown. This has been shown to be more accurate than conventionally used two-dimensional models. The growth of the communications industry has also imposed a demand for increased data rates for the transmission of large volumes of data. To achieve increased data rates, complex modulation and multiple access techniques are employed requiring minimum distortion of the signal as it is passed through the TWT. Thus, intersymbol interference (ISI) becomes a major consideration, as well as suspected causes such as reflections within the TWT. To experimentally investigate effects of the physical TWT on ISI would be prohibitively expensive, as it would require manufacturing numerous amplifiers, in addition to acquiring the required digital hardware. As an alternative, the time-domain TWT interaction model developed here provides the capability to establish a computational test bench where ISI or bit error rate can be simulated as a function of TWT operating parameters and component geometries. Intermodulation products, harmonic generation, and backward waves can also be monitored with the model for similar correlations. The advancements in computational capabilities and corresponding potential improvements in TWT performance may prove to be the enabling technologies for realizing unprecedented data rates for near real time transmission of the increasingly larger volumes of data demanded by planned commercial and Government satellite communications applications. This work is in support of the Cross Enterprise Technology Development Program in Headquarters' Advanced Technology & Mission Studies Division and the Air Force Office of Scientific Research Small Business Technology Transfer programs.

Kory, Carol L.↗

NASA NTRS2019

The Solar Clock

The Sun is powered by a very stable source of fusion energy in its core that radiates that energy outward in a constant flow. Yet it has a cycle of magnetic dynamo activity whose strength and duration are variable. This variability, which affects the Earth's â€˜space climate', points to temporal changes in the convective and diffusive transport of magnetic flux above the tachocline, where the flux is generated. The longest record we have of this variability is the time series of Sunspot Numbers (SSN). This record suggests that the interior of the Sun follows a clocklike magnetic flux production cycle with a length of close to 11.05 yr. The variations in sunspot cycle duration, as well as the sunspot number rise and fall times, their hemispheric asymmetries, and the maximum sunspot numbers of the individual cycles, are likely produced in the process of the magnetic flux transport. Helioseismology continues to shed more light on the convection zone variabilities, including the â€˜torsional oscillations' that seem to have a special connection to the emerging strong magnetic fluxes that produce the sunspots. These new observations may eventually lead to an explanation for the surprisingly good correlation between the rate of sunspot appearance and the maximum sunspot number, and to a better understanding of the relationship between the solar dynamo and the sunspot number cycle. Better understanding of the polar regions awaits long-term monitoring with a polar solar mission. Better predictions of nearterm space weather could be obtained from a permanent L5 monitor.

C T Russell↗

NASA NTRS2011

Programmable Aperture with MEMS Microshutter Arrays

A microshutter array (MSA) has been developed for use as an aperture array for multi-object selections in James Webb Space Telescope (JWST) technology. Light shields, molybdenum nitride (MoN) coating on shutters, and aluminum/aluminum oxide coatings on interior walls are put on each shutter for light leak prevention, and to enhance optical contrast. Individual shutters are patterned with a torsion flexure that permits shutters to open 90 deg. with a minimized mechanical stress concentration. The shutters are actuated magnetically, latched, and addressed electrostatically. Also, micromechanical features are tailored onto individual shutters to prevent stiction. An individual shutter consists of a torsion hinge, a shutter blade, a front electrode that is coated on the shutter blade, a backside electrode that is coated on the interior walls, and a magnetic cobalt-iron coating. The magnetic coating is patterned into stripes on microshutters so that shutters can respond to an external magnetic field for the magnetic actuation. A set of column electrodes is placed on top of shutters, and a set of row electrodes on sidewalls is underneath the shutters so that they can be electrostatically latched open. A linear permanent magnet is aligned with the shutter rows and is positioned above a flipped upside-down array, and sweeps across the array in a direction parallel to shutter columns. As the magnet sweeps across the array, sequential rows of shutters are rotated from their natural horizontal orientation to a vertical open position, where they approach vertical electrodes on the sidewalls. When the electrodes are biased with a sufficient electrostatic force to overcome the mechanical restoring force of torsion bars, shutters remain latched to vertical electrodes in their open state. When the bias is removed, or is insufficient, the shutters return to their horizontal, closed positions. To release a shutter, both the electrode on the shutter and the one on the back wall where the shutter sits are grounded. The shutters with one or both ungrounded electrodes are held open. Sub-micron bumps underneath light shields and silicon ribs on back walls are the two features to prevent stiction. These features ensure that the microshutter array functions properly in mechanical motions. The MSA technology can be used primarily in multi-object imaging and spectroscopy, photomask generation, light switches, and in the stepper equipment used to make integrated circuits and MEMS (microelectromechanical systems) devices.

Moseley, Samuel↗

NASA NTRS1989

Design of a lunar transportation system

The development of a good transportation infrastructure is a major requirement for the establishment of a permanent lunar base. Transportation is characterized by the technology available in a specific time frame and the need to transport personnel and cargo between Earth and Moon, and between lunar bases. In our study, attention was first focused on developing a transportation system for the first generation lunar base. As a first step, a tracked-type multipurpose lunar transportation vehicle was considered as a possible mode of transportation and a detailed study was conducted on the various aspects of the vehicle. Since the vehicle is composed of many moving parts, exposing it to the environment of the Moon, where fine dust particles are prevalent, can cause problems associated with lubrication and friction. The vehicle also posed problems concerning weight and power. Hence, several modifications were made to the above design ideas conceptually, and a Lunar Articulated Remote Transportation System (Lunar ARTS) is proposed as a more effective alternative with the following objectives: (1) minimizing the transportation of construction material and fuel from Earth or maximizing the use of the lunar material; (2) use of novel materials and light-weight structures; (3) use of new manufacturing methods and technology such as magnetic levitation using superconducting materials; and (4) innovative concepts of effectively utilizing the exotic lunar conditions, i.e., high thermal gradients, lack of atmosphere, lower gravity, etc. To achieve the above objectives of designing transportation systems from concept to operation, the project was planned in three phases: (1) conceptual design; (2) detailed analysis and synthesis; and (3) construction, testing, evaluation, and operation. In this project, both phases 1 and 2 have been carried out and work on phase 3 is in progress. In this paper, the details of the Lunar ARTS are discussed and the future work on the vehicle are also outlined.

Sankaravelu, A.↗

NASA NTRS1995

Nearly sonic and transsonic convective motions in the solar atmosphere related to the solar wind origin

MHD equations are considered for the solar atmosphere. 15 different simplest MHD regimes are indicated for the momentum transport equation depending on the mutual binary interplay between 6 possible and locally dominant terms: non-stationarity and inhomogeneity of the flow, gas pressure, magnetic tensions, viscous and gravity forces. These regimes are delimited by five physically independent dimensionless parameters, for example, Strouhal, sonic Mach, alfvenic Mach, Reynolds and Froude numbers or their combinations. Another partially overlapping classification of the simplest regimes may be introduced based on the energy conservation equation. There are also 15 independent binary combinations between nonstationary and inhomogeneous convective terms, dissipative energy sinks and sources (viscous, heat-conductive, Joule and radiative ones) in the energy equation. More complicated regimes are considered with multiple dominated terms. All these MHD regimes play their important role somewhere in the solar atmosphere complicated by the tensor transport coefficients in the magnetically dominated regions of the upper atmosphere. Nearly sonic and transsonic nonstationary convective motions with ascending and descending flows are observed in the solar chromosphere. the transition region and the lower pans of the solar corona together with related horizontal velocity components. This convection represents a kind of the 'cocoonery' manufacturing nonstationary vortices generated here and partially connected to the photosphere and to the solar wind. The solar wind originates from this powerful transsonic muddle in the solar atmosphere as a tiny fraction of the streamlines which are temporarily getting detached from the 'cocoons; and going to the infinity. The topologically complicated instantaneous 'runaway surface' around the Sun, i.e., the surface which separates outgoing to the infinity streams from other finite flows in the solar atmosphere was not described in the literature and needs additional investigation. We conclude that a simple one-connected smooth and quasistationary 'critical surface' which is often supposed to be placed somewhere in the solar corona (say, at 4 solar radii) in reality does not exist. Observational and theoretical arguments favor instead of this a highly structured, disordered, patched and time-dependent sonic transition surface in the solar atmosphere permanently fluctuating at positional dependent heights starting sometimes from photospheric (and maybe subphotospheric) levels and more frequently from the chromosphenc network up to several solar radii in the solar corona.

Veselovsky, I. S.↗

NASA NTRS2001

Stirling Technology Development at NASA GRC

The Department of Energy, Stirling Technology Company (STC), and NASA Glenn Research Center (NASA Glenn) are developing a free-piston Stirling convertor for a high efficiency Stirling Radioisotope Generator (SRG) for NASA Space Science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. NASA Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. Recent testing of 55-We Technology Demonstration Convertors (TDCs) built by STC includes mapping of a second pair of TDCs, single TDC testing, and TDC electromagnetic interference and electromagnetic compatibility characterization on a nonmagnetic test stand. Launch environment tests of a single TDC without its pressure vessel to better understand the convertor internal structural dynamics and of dual-opposed TDCs with several engineering mounting structures with different natural frequencies have recently been completed. A preliminary life assessment has been completed for the TDC heater head, and creep testing of the IN718 material to be used for the flight convertors is underway. Long-term magnet aging tests are continuing to characterize any potential aging in the strength or demagnetization resistance of the magnets used in the linear alternator (LA). Evaluations are now beginning on key organic materials used in the LA and piston/rod surface coatings. NASA Glenn is also conducting finite element analyses for the LA, in part to look at the demagnetization margin on the permanent magnets. The world's first known integrated test of a dynamic power system with electric propulsion was achieved at NASA Glenn when a Hall-effect thruster was successfully operated with a free-piston Stirling power source. Cleveland State University is developing a multidimensional Stirling computational fluid dynamics code to significantly improve Stirling loss predictions and assist in identifying convertor areas for further improvements. This paper will update the status and results for these efforts.

Thieme, Lanny G.↗

NASA NTRS2002

Stirling Technology Development at NASA GRC

The Department of Energy, Stirling Technology Company (STC), and NASA Glenn Research Center (NASA Glenn) are developing a free-piston Stirling convertor for a high-efficiency Stirling Radioisotope Generator (SRG) for NASA Space Science missions. The SRG is being developed for multimission use, including providing electric power for unmanned Mars rovers and deep space missions. NASA Glenn is conducting an in-house technology project to assist in developing the convertor for space qualification and mission implementation. Recent testing, of 55-We Technology Demonstration Convertors (TDC's) built by STC includes mapping, of a second pair of TDC's, single TDC testing, and TDC electromagnetic interference and electromagnetic compatibility characterization on a nonmagnetic test stand. Launch environment tests of a single TDC without its pressure vessel to better understand the convertor internal structural dynamics and of dual-opposed TDC's with several engineering mounting structures with different natural frequencies have recently been completed. A preliminary life assessment has been completed for the TDC heater head, and creep testing of the IN718 material to be used for the flight convertors is underway. Long-term magnet aging tests are continuing to characterize any potential aging in the strength or demagnetization resistance of the magnets used in the linear alternator (LA). Evaluations are now beginning on key organic materials used in the LA and piston/rod surface coatings. NASA Glenn is also conducting finite element analyses for the LA, in part to look at the demagnetization margin on the permanent magnets. The world's first known integrated test of a dynamic power system with electric propulsion was achieved at NASA Glenn when a Hall-effect thruster was successfully operated with a free-piston Stirling power source. Cleveland State University is developing a multidimensional Stirling computational fluid dynamics code to significantly improve Stirling loss predictions and assist in identifying convertor areas for further improvements. This paper will update the status and results for these efforts.

Thieme, Lanny G.↗

NASA NTRS2008

Science on the Moon: The Wailing Wall of Space Exploration

Science on and from the Moon has important implications for expanding human knowledge and understanding, a prospect for the 21st Century that has been under discussion for at least the past 25 years. That having been said, however, there remain many issues of international versus national priorities, strategy, economy, and politics that come into play. The result is a very complex form of human behavior where science and exploration take center stage, but many other important human options are sacrificed. To renew this dialogue about the Moon, it seems we are already rushing pell-mell into it as has been done in the past. The U.S., Japan, China, India, and Russia either have sent or plan to send satellites and robotic landers there at this time. What does a return to the Moon mean, why are we doing this now, who should pay for it, and how? The only semblance of such a human enterprise seems to be the LHC currently coming online at CERN. Can it be used as a model of international collaboration rather than a sports or military event focused on national competition? Who decides and what is the human sacrifice? There are compelling arguments for establishing science on the Moon as one of the primary goals for returning to the Moon and venturing beyond. A number of science endeavors will be summarized, beyond lunar and planetary science per se. These include fundamental physics experiments that are background-limited by the Earth's magnetic dipole moment and noise produced by its atmosphere and seismic interior. The Moon is an excellent platform for some forms of astronomy. Other candidate Moon-based experiments vary from neutrino and gravitational wave astronomy, particle astrophysics, and cosmic-ray calorimeters, to space physics and fundamental physics such as proton decay. The list goes on and includes placing humans in a hostile environment to study the long-term effects of space weather. The list is long, and even newer ideas will come from this COSPAR conference. However, whatever the list the issue of cooperation and binding collaboration remains. As observers of Moon and other space enterprises, we all know that a room full of 60 scientists will not agree on much of anything and there will probably be 60! please for more funding. People have special interests and little common sense (e.g., conflict between NSF- and NASA-funding roadmaps). Scientists are no exception. Nevertheless, CERN has done it on Earth! Can we do the same on the Moon? Some of the present generation of proposals for science from and on the Moon, plus new ones, will witness a place in space exploration's future. It is clear, however, that the world has not thought this through adequately, except for talk about an international space federation whatever that is. An outpost on the Moon with humans permanently living there much like Antarctica on Earth may be in our future. However, such planning is our collective international responsibility and not that of special-interest investigators from individual nations unless they intend to pay for it.

Wilson, Thomas↗

DOE OSTI2022

A compact design for an electric driven hydraulic gear machine capable of multiple quadrant operation

This paper presents an innovative design of an integrated electro-hydraulic (EH) flow generation unit able to operate in multiple quadrants. The proposed unit is composed of a hydraulic machine which can operate in either pumping or motoring mode, and an electric machine, which can operate as electric motor or generator. The adopted morphological integration of the two unit fulfills the goals of maximizing compactness, power to weight ratio, energy efficiency and quietness. Furthermore, the design results from a numerical optimization procedure that includes detailed simulation of both the electric machine and the hydraulic machine, using simulation tools previously developed by the authors, but combined for the first time in this work. After describing the optimization procedure, the paper focuses on the design integration aspects of the novel unit. A 9 kW prototype of the integrated unit was also fabricated and tested to verify its performance. Tests results show a measured overall energy efficiency up to 69%, demonstrating the potentials of the proposed concept, despite some limitations present in the first prototypes which could be addressed in future design refinements.

42 ENGINEERING↗

NASA NTRS2003

Overview of NASA GRC Stirling Technology Development

The Stirling Radioisotope Generator (SRG) is currently being developed by Lockheed Martin Astronautics (LMA) under contract to the Depar1ment of Energy (DOE). The generator will be a high efficiency electric power source for NASA Space Science missions with the capability to operate in the vacuum of deep space or in an atmosphere such as on the surface of Mars. High system efficiency is obtained through the use of free-piston Stirling power conversion technology. Power output of the generator will be greater than 100 watts at the beginning of life with the decline in power being largely due to the decay of the plutonium heat source. In suppOl1 of the DOE SRG project, the NASA Glenn Research Center (GRC) has established a near-term technology effort to provide some of the critical data to ensure a successful transition to flight for what will be the first dynamic power system used in space. Initially, a limited number of technical areas were selected for the GRC effort, however this is now being expanded to more thoroughly cover a range of technical issues. The tasks include in-house testing of Stirling convertors and controllers, materials evaluation and heater head life assessment, structural dynamics, electromagnetic interference, organics evaluation, and reliability analysis. Most of these high-level tasks have several subtasks within. There is also an advanced technology effort that is complementary near-term technology effort. Many of the tests make use of the 55-We Technology Demonstration Convel10r (TDC). There have been multiple controller tests to support the LMA flight controller design effort. Preparation is continuing for a thermal/vacuum system demonstration. A pair of flight prototype TDC's have recently been placed on an extended test with unattended, continuous operation. Heater head life assessment efforts continue, with the material data being refined and the analysis moving toward the system perspective. Long-term magnet aging tests are continuing to characterize any possible aging in the strength or demagnetization resistance of the permanent magnets used in the linear alternator. In a parallel effort, higher performance magnets are also being evaluated. A reliability effort is being initiated that will help to guide the development activities with an increased focus on the necessary components and subsystems. Some other disciplines that are active in the GRC technology effort include structural dynamics, linear alternator analysis, EMI/EMC, controls, and mechanical design evaluation. This paper will provide an overview of some of the GRC technical efforts, including the current status, and a description of future efforts.

Schreiber, Jeffrey↗

NASA NTRS2009

NanoSail-D: A Solar Sail Demonstration Mission

During the past decade, within the United States, NASA Marshall Space Flight Center (MSFC) was heavily engaged in the development of revolutionary new technologies for in-space propulsion. One of the major in-space propulsion technologies developed was a solar sail propulsion system. Solar sail propulsion uses the solar radiation pressure exerted by the momentum transfer of reflected photons to generate a net force on a spacecraft. To date, solar sail propulsion systems have been designed for large spacecraft in the tens to hundreds of kilograms mass range. Recently, however, MSFC has been investigating the application of solar sails for small satellite propulsion. Likewise, NASA Ames Research Center (ARC) has been developing small spacecraft missions that have a need for amass-efficient means of satisfying deorbit requirements. Hence, a synergistic collaboration was established between these two NASA field Centers with the objective of conducting a flight demonstration of solar sail technologies for small satellites. The NanoSail-D mission flew onboard the ill-fated Falcon Rocket launched August 2, 2008, and, due to the failure of that rocket, never achieved orbit. The NanoSail-D flight spare is ready for flight and a suitable launch arrangement is being actively pursued. Both the original sailcraft and the flight spare are hereafter referred to as NanoSail-D. The sailcraft consists of a sail subsystem stowed in a three-element CubeSat. Shortly after deployment of the NanoSail-D, the solar sail will deploy and mission operations will commence. This demonstration flight has two primary technical objectives: (1) to successfully stow and deploy the sail and (2) to demonstrate deorbit functionality. Given a near-term opportunity for launch on Falcon, the project was given the challenge of delivering the flight hardware in 6 mo, which required a significant constraint on flight system functionality. As a consequence, passive attitude stabilization of the spacecraft will be achieved using permanent magnets to detumble and orient the body with the magnetic field lines and then rely on atmospheric drag to passively stabilize the sailcraft in an essentially maximum drag attitude. This paper will present an introduction to solar sail propulsion systems and an overview of the NanoSail-D spacecraft.

Johnson, Les↗

NASA NTRS2001

Assessment of Stirling Technology Has Provided Critical Data Leading Toward Flight Readiness of the Stirling Converter

The NASA Glenn Research Center is supporting the development of a Stirling converter with the Department of Energy (DOE, Germantown, Maryland) for an advanced Stirling Radioisotope Power System (SRPS) to provide spacecraft onboard electric power for NASA space science missions. A key technology assessment completed by Glenn and DOE has led to the SRPS being identified as a high-efficiency power source for such deep space missions as the Europa Orbiter and the Solar Probe. In addition, the Stirling system is now being considered for unmanned Mars rovers, especially where mission profiles may exclude the use of photovoltaic power systems, such as exploration at high Martian latitudes or for missions of long duration. The SRPS efficiency of over 20 percent will reduce the required amount of radioisotope by more than a factor of 3 in comparison to current radioisotope thermoelectric generators. This significantly reduces radioisotope cost, radiological inventory, and system cost, and it provides efficient use of scarce radioisotope resources. In support of this technology assessment, Glenn conducted a series of independent evaluations and tests to determine the technology readiness of a 55-We Stirling converter developed by Stirling Technology Company (Kennewick, Washington) and DOE. Key areas evaluated by Glenn included: 1) Radiation tolerance of materials; 2) Random vibration testing of the Stirling converter in Glenn's Structural Dynamics Lab to simulate operation in the launch environment; 3) Electromagnetic interference and compatibility (EMI/EMC) of the converter operating in Glenn's EMI lab; Independent failure modes, effects, and criticality analysis, and life and reliability 4. Independent failure modes, effects, and criticality analysis, and life and reliability assessment; and 5) SRPS cost estimate. The data from these evaluations were presented to NASA Headquarters and the Jet Propulsion Laboratory mission office by a joint industry/Government team consisting of DOE, Glenn, and Lockheed Martin Astronautics. This team concluded that there are no technical reasons that would rule out using the Stirling converter for deep space missions. As a direct result of the successful testing at Glenn, the DOE/Stirling Technology Company 55-We Stirling converter has been baselined for the SRPS. Glenn is now continuing an in-house project to assist in developing the Stirling converter for readiness for space qualification and mission implementation. As part of this effort, the Stirling converter will be further characterized under launch environment random vibration testing, methods to reduce converter EMI will be developed, and an independent performance verification will be completed. Converter life assessment and permanent magnet aging characterization tasks are also underway. Substitute organic materials for the linear alternator and piston bearing coatings for use in a high-radiation environment have been identified and have now been incorporated in Stirling converters built by Stirling Technology Company for Glenn. Electromagnetic and thermal finite element analyses for the alternator are also being conducted.

Thieme, Lanny G.↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off (PTO) system, which is the mechanism by which the energy absorbed by the prime mover is transformed into useable electrical. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency) and devices will see a sinusoidally varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled PTOs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the DOE sponsored Reference Model Project (RMP). The RMP was a partnered effort to develop open-source marine energy (ME) point designs as reference models (RMs) to benchmark ME technology performance and costs, methods for design and analysis of ME technologies, estimations for capital costs, operational costs, and levelized costs of energy (LCOE). The results from this study show torque is directly related to (1) the physical size of the machine required to increase the airgap sheer stresses, (2) the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both CAPEX and OPEX. This paper aims to be a critical benchmark in helping determine an “optimal” nameplate rating for wave energy devices and their associated PTO. With an optimized rating and sizing process, WEC costs can be reduced, and overall performance can be improved.

cables↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters: Preprint

cables↗

DOE OSTI2020

Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines

To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Techno-Economic Implications of Electrical Machine Scaling for Wave Energy Converters

The sizing of an electrical machine for a Wave Energy Converter (WEC) can have a substantial impact on the overall sizing, cost, and rating of the device. An electrical generator is typically part of the power take-off system, which is the mechanism by which the energy absorbed by the prime mover is transformed into usable electrical energy. For practically all WECs, the rate of change of actuation is predominantly determined by the wave resource (i.e., the wave height and frequency), and devices will see a sinusoidal varying velocity according to the wave conditions. The same can then be said for both directly and indirectly coupled power take-offs with electrical generators. This techno-economic study investigates electrical machine scaling and associated cost implications through core machine design theory, manufacturer data, supporting literature, and the Reference Model Project sponsored by the U.S. Department of Energy. The Reference Model Project was a partnered effort to develop open-source marine energy point designs as reference models to benchmark marine energy technology performance and costs, methods for design and analysis of marine energy technologies, estimations for capital costs, operational costs, and levelized cost of energy. The results from this study show torque is directly related to (1) the physical size of the machine required to increase the air-gap sheer stresses, (2)the amount of active material, (3) the support structure, (4) bearing size and rating, and (5) offshore cable rating, all of which have a significant effect on overall system costs in terms of both capital and operational expenditures. This paper aims to be a critical benchmark in helping determine an "optimal" nameplate rating for wave energy devices and their associated power take-offs. With an optimized rating and sizing process, WEC costs can be reduced and overall performance can be improved.

cables↗

DOE OSTI2026

Cyclodextrin-Derived Porous Liquids Enabled by In Situ Solvation Shell Formation

Porous liquids (PLs) represent a unique platform for molecular separations by combining permanent porosity with liquid-phase mobility. However, it remains a formidable challenge to construct and stabilize PLs with sub-5 Å pores using readily available porous host and liquid media. Here, we report the construction of cyclodextrin (CD)-derived PLs enabled by in situ solvation shell formation. The acid–base neutralization reaction between CD and an organic base was leveraged to generate a thin ionic solvation shell around the CD host, effectively liquefying CD and preventing its segregation in the liquid base medium while preserving accessible molecular-scale cavities. Spectroscopic analysis, neutron scattering, density functional theory calculations, and molecular dynamics simulations collectively confirm the structural evolution and existence of abundant internal porosity in PLs. The unique architectures of CD-derived PLs enable highly selective encapsulation of fluorinated alkanes and significantly enhanced uptake of inert gases. This facile and generalizable strategy enables construction of high-quality PLs with engineered ultramicroporosity to facilitate molecular separations.

Cavities↗