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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Friction consolidation of gas-atomized Fe−Si powders for soft magnetic applications

Soft magnetic materials are often limited in scalability due to conventional processes that do not retain beneficial microstructures, and their associated physical properties, during densification. In this work, friction consolidation (FC) has been studied to fabricate Fe−Si soft magnetic materials from gas-atomized powder precursors. Fe−Si powder is consolidated using variable pressure and tool rotation speed in an effort to evaluate this unique densification approach for potential improvements in magnetic properties. FC, due to the high shear deformation involved, is shown to result in uniform gradual grain structure refinement across the consolidated workpiece from the center nearest the tool to the edge. Magnetic properties along different orientations indicate little, if any, textural orientation in the refined grain structure. The effect of annealing on the magnetic properties is evaluated and shown to decrease coercivity. FC processing was able to retain the magnetization of the original gas-atomized powders but further process optimization is needed to reach the optimal coercivity for the soft magnetic materials applications. - Highlights: •Friction stir processing was utilized to consolidate Fe−Si soft magnetic powders. •The resultant microstructure and magnetic properties were correlated to the processing conditions. •Friction consolidation refined the grain size of the materials by ~ 40%. •Annealing successfully reduced the coercivity induced by the stress during processing. •The results shine light on the possible scaling up of nanostructured materials.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Dual magnetic phase material rings for AC electric machines

An AC electric machine that includes a dual magnetic phase material ring is disclosed. The AC electric machine includes a stator assembly and a rotor assembly positioned within the stator assembly and configured to rotate relative thereto, the rotor assembly comprising a rotor core including a stack of rotor laminations that collectively form the rotor core, the rotor core including a plurality of rotor poles separated by gaps therebetween. The AC electric machine also includes a dual magnetic phase material ring positioned about the stack of rotor laminations, the dual magnetic phase material ring comprising a first ring portion comprising a magnetic portion and a second ring portion comprising a non-magnetic portion.

42 ENGINEERING↗
DOE OSTI2015

Synthesis, microstructure and magnetic properties of Fe{sub 3}Si{sub 0.7}Al{sub 0.3}@SiO{sub 2} core–shell particles and Fe{sub 3}Si/Al{sub 2}O{sub 3} soft magnetic composite core

Fe{sub 3}Si{sub 0.7}Al{sub 0.3}@SiO{sub 2} core–shell particles and Fe{sub 3}Si/Al{sub 2}O{sub 3} soft magnetic composite core have been synthesized via a modified stöber method combined with following high temperature sintering process. Most of conductive Fe{sub 3}Si{sub 0.7}Al{sub 0.3} particles could be uniformly coated by insulating SiO{sub 2} using the modified stöber method. The Fe{sub 3}Si{sub 0.7}Al{sub 0.3}@SiO{sub 2} core–shell particles exhibited good soft magnetic properties with low coercivity and high saturation magnetization. The reaction 4Al+3SiO{sub 2}=2α-Al{sub 2}O{sub 3}+3Si took place during the sintering process. As a result the new Fe{sub 3}Si/Al{sub 2}O{sub 3} composite was formed. The Fe{sub 3}Si/Al{sub 2}O{sub 3} composite core displayed more excellent soft magnetic properties, better frequency stability at high frequencies, much higher electrical resistivity and lower core loss than the pure Fe{sub 3}Si{sub 0.7}Al{sub 0.3} core. The method of introducing insulating layers surrounding magnetic particles provides a promising route to develop new and high compact soft magnetic materials with good magnetic and electric properties. - Graphical abstract: In Fe{sub 3}Si/Al{sub 2}O{sub 3} composite, Fe{sub 3}Si phases are separated by Al{sub 2}O{sub 3} layers and the eddy currents are confined in Fe{sub 3}Si phases, thus increasing resistivity and reducing core loss. - Highlights: • Fe{sub 3}Si{sub 0.7}Al{sub 0.3}@SiO{sub 2} core–shell particles and Fe{sub 3}Si/Al{sub 2}O{sub 3} cores were prepared. • Fe{sub 3}Si{sub 0.7}Al{sub 0.3} particles could be uniformly coated by nano-sized SiO{sub 2} clusters. • Fe{sub 3}Si{sub 0.7}Al{sub 0.3}@SiO{sub 2} particles and Fe{sub 3}Si/Al{sub 2}O{sub 3} cores showed good soft magnetic properties. • Fe{sub 3}Si/Al{sub 2}O{sub 3} had lower core loss and better frequency stability than Fe{sub 3}Si{sub 0.7}Al{sub 0.3} cores.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Inter-grain interaction in random magnetic anisotropy simulation in magnetic nanocrystals

Effect of inter-grain exchange interaction on the coercive forces was analyzed with a numerical simulation in magnetic materials with random magnetic anisotropy. The magnetization of an assembly of magnetically interacting grains with randomly oriented uniaxial anisotropy was calculated using the Landau-Lifshitz-Gilbert equation. We supposed a single spin model where the magnetizations in a grain were aligned in the same direction, for simplicity. Calculations were carried out for an N×N×N system, where the number of grains on a side, N ranged from 16 to 128. The relation between the coercive forces H{sub C} and the grain size D is represented by H{sub C}∝D{sup k}. With the increase of N, k decreased gradually and tended to reach a saturated value around k = 4.5–5, which dose not correspond to the primitive theory of the random anisotropy model where k = 6. The deviation was discussed in terms of the inter-grain interaction, essentially proportional to the inverse of D.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Circumventing data imbalance in magnetic ground state data for magnetic moment predictions

Abstract Magnetic materials play a crucial role in the transition to more sustainable forms of energy and electric vehicles. There is an anticipated shortage in magnetic materials in the future, and as a result there is an urgent need to discover and design new magnetic materials. Computational magnetic material design using density functional theory is daunting because of the challenge in identifying magnetic ground states from a combinatorially large set of possibilities. Machine learning offers a path forward by enabling efficient surrogate models that can more readily enumerate these states, but there is a dearth of training data available, and what is available tends to be imbalanced with too much non-magnetic data. In this work we show that the discrete and previously tackled data imbalance that exists at the level of the magnetic ordering leads to an imbalanced continuous distribution with many zeros when the data is unraveled at the atomic magnetic moment level, which subsequently leads to models with low accuracy for magnetic properties. We mitigate this by using a two-part model framework. Our scheme is able to classify atoms into magnetic and non-magnetic with an F1 score and Matthew’s correlation coefficient (MCC) of ~91% and then to provide an implicit embedding representation that maps directly onto the magnitude of the magnetic moment with a mean absolute error of 0.1 μ B . Beyond screening for new magnetic materials, we demonstrate an additional practical use case of our scheme: the provision of good initial guesses for magnetic moments in first-principles electronic relaxations. Such initialization is shown to lead to faster convergence to configurations that lie closer to the ground state.

Computer Science↗
DOE OSTI2020

Magnetic feed material and its use in producing bonded permanent magnets by additive manufacturing

A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Highly-­laminated, high-­saturation-flux-­density, magnetic cores for on-­chip inductors in power converter applications

The objective of this project is development of a manufacturing process to realize thick highly-laminated metallic magnetic cores with suppressed eddy current losses for power applications and demonstration of integrated magnetic components using the process. The continual reduction in size and increase in functionality of portable electronic devices drives the development of ultracompact electrical power converters and therefore their associated inductors, which typically occupy the largest volume within the converter. This inductor size reduction can be achieved by increasing both the converter switching frequency as well as inductor operating flux density by utilizing appropriate magnetic core materials. Magnetically soft metallic alloys (e.g., NiFe and CoNiFe) are good core material candidates due to their superior magnetic properties (e.g., high saturation flux density and low coercivity) compared to conventional ferrite. However, to minimize eddy current losses, the core thickness is limited to the skin depth (typically less than 3 µm for 10 MHz operation); cores of this thickness are likely insufficient for handling high power (> 10W). Therefore, there is great interest in the development of highly-laminated metallic alloy cores with single lamination thickness in the sub-micron range to achieve suppressed eddy-current losses and high power handling capacity simultaneously. During the project, highly-laminated metallic alloy cores comprising up to 2000 layers of permalloy (Ni 80 Fe 20 ) or CoNiFe materials with single lamination thickness less than 1 µm have been fabricated based on automated multilayer electrodeposition technology compatible with CMOS manufacturing. The developed highly-laminated metallic cores preserve the high saturation flux density and low coercivity characteristics of metallic alloys, while suppressing eddy-current losses less than 1 W/cm3 at operation flux density of 0.5 T and frequency over 1 MHz. The developed highly-laminated metallic alloy cores have been further integrated into microfabricated windings to realize compact, on-chip inductors. Utilizing CMOS-compatible integration techniques, circular (toroid) and bar-shape (solenoid) microinductors have been fabricated exhibiting a constant inductance higher than 1 µH up to 50 MHz with peak quality factor as high as 35 at 5 MHz. The microfabricated inductor with highly-laminated core was tested in a power converter and demonstrated a converter efficiency of 93% at 5.5 MHz and 42 W under 100V input and 35V output operation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2013

Multiphase Resistivity Model for Magnetic Nanocomposites Developed for High Frequency, High Power Transformation

New power conversion systems that offer promise to transform electricity grids into unified interactive supply networks require high-resistivity soft-magnetic materials to allow for switching of magnetic materials at frequencies approaching 100 kHz for power transformation in the megawatt range. Amorphous and nanocomposite soft-magnetic materials, which represent the state of the art in terms of high power densities and low losses at high frequencies, have resistivities that depend on the structures and spatial distributions of multiple phases in thin ribbons. We present a multiphase resistivity model applicable to nanocomposite materials by considering an equivalent circuit approach considering paths through an amorphous, crystalline, and growth inhibitor shell phase. We detail: (a) identification of amorphous, crystalline, and shell phases; (b) consideration of the role of the morphology of each phase in an equivalent circuit model for the resistance; (c) a two-band model for the Fe/Co composition dependence of the resistivity in crystalline and amorphous phases; (d) a virtual bound state model for resistivity to explain increased resistivity due to early transition-metal growth inhibitors in the shell surrounding the nanocrystalline phase; and (e) disorder effects on amorphous phase resistivity. Experimental design and results for systems of interest in high-frequency power transformation are discussed in the context of our model including: (a) techniques for measurements of cross-section and density, (b) four-point probe and surface resistivity measurements, and (c) measurements in Fe- and Co-rich systems comparing amorphous and nanocomposite materials.

DeGeorge, V↗
DOE OSTI2024

Observation of plaid-like spin splitting in a noncoplanar antiferromagnet

Spatial, momentum and energy separation of electronic spins in condensed matter systems guides the development of novel devices where spin-polarized current is generated and manipulated. Recent attention on a set of previously overlooked symmetry operations in magnetic materials leads to the emergence of a new type of spin splitting, enabling giant and momentum-dependent spin polarization of energy bands on selected antiferromagnets. Despite the ever-growing theoretical predictions, the direct spectroscopic proof of such spin splitting is still lacking. Here, we provide solid spectroscopic and computational evidence for the existence of such materials. In the noncoplanar antiferromagnet MnTe 2 , the in-plane components of spin are found to be antisymmetric about the high-symmetry planes of the Brillouin zone, comprising a plaid-like spin texture in the antiferromagnetic (AFM) ground state. Such an unconventional spin pattern, further found to diminish at the high- temperature paramagnetic state, stems from the intrinsic AFM order instead of spin- orbit coupling (SOC). Furthermore, our finding demonstrates a new type of quadratic spin texture induced by time-reversal breaking, placing AFM spintronics on a firm basis and paving the way for studying exotic quantum phenomena in related materials.

Electronic devices↗
DOE OSTI2017

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

A bulk permanent magnetic material may include between about 5 volume percent and about 40 volume percent Fe16N2 phase domains, a plurality of nonmagnetic atoms or molecules forming domain wall pinning sites, and a balance soft magnetic material, wherein at least some of the soft magnetic material is magnetically coupled to the Fe16N2 phase domains via exchange spring coupling. In some examples, a bulk permanent magnetic material may be formed by implanting N+ ions in an iron workpiece using ion implantation to form an iron nitride workpiece, pre-annealing the iron nitride workpiece to attach the iron nitride workpiece to a substrate, and post-annealing the iron nitride workpiece to form Fe16N2 phase domains within the iron nitride workpiece.

36 MATERIALS SCIENCE↗
DOE OSTI2020

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

A bulk permanent magnetic material may include between about 5 volume percent and about 40 volume percent Fe16N2 phase domains, a plurality of nonmagnetic atoms or molecules forming domain wall pinning sites, and a balance soft magnetic material, wherein at least some of the soft magnetic material is magnetically coupled to the Fe16N2 phase domains via exchange spring coupling. In some examples, a bulk permanent magnetic material may be formed by implanting N+ ions in an iron workpiece using ion implantation to form an iron nitride workpiece, pre-annealing the iron nitride workpiece to attach the iron nitride workpiece to a substrate, and post-annealing the iron nitride workpiece to form Fe16N2 phase domains within the iron nitride workpiece.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

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

A bulk permanent magnetic material may include between about 5 volume percent and about 40 volume percent Fe16N2 phase domains, a plurality of nonmagnetic atoms or molecules forming domain wall pinning sites, and a balance soft magnetic material, wherein at least some of the soft magnetic material is magnetically coupled to the Fe16N2 phase domains via exchange spring coupling. In some examples, a bulk permanent magnetic material may be formed by implanting N+ ions in an iron workpiece using ion implantation to form an iron nitride workpiece, pre-annealing the iron nitride workpiece to attach the iron nitride workpiece to a substrate, and post-annealing the iron nitride workpiece to form Fe16N2 phase domains within the iron nitride workpiece.

Wang, Jian-Ping↗
DOE OSTI2015

Automated setup for magnetic hysteresis characterization based on a voltage controlled current source with 500 kHz full power bandwidth and 10 A peak-to-peak current

This paper describes the design of a system for the characterization of magnetic hysteresis behavior in soft ferrite magnetic cores. The proposed setup can test magnetic materials exciting them with controlled arbitrary magnetic field waveforms, including the capability of providing a DC bias, in a frequency bandwidth up to 500 kHz, with voltages up to 32 V peak-to-peak, and currents up to 10 A peak-to-peak. In order to have an accurate control of the magnetic field waveform, the system is based on a voltage controlled current source. The electronic design is described focusing on closed loop feedback stabilization and passive components choice. The system has real-time hysteretic loop acquisition and visualization. The comparisons between measured hysteresis loops of sample magnetic materials and datasheet available ones are shown. Results showing frequency and thermal behavior of the hysteresis of a test sample prove the system capabilities. Moreover, the B-H loops obtained with a multiple waveforms excitation signal, including DC bias, are reported. The proposal is a low-cost and replicable solution for hysteresis characterization of magnetic materials used in power electronics.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Electric Motor Thermal Management Research: Annual Progress Report

Past work in the area of active convective cooling provided data on the average convective heat transfer coefficients of circular orifice automatic transmission fluid (ATF) jets impinging on stationary targets intended to represent the wire bundle surface of the motor end-winding. Work during FY16 focused on the impact of alternative jet geometries that could lead to improved cooling over a larger surface of the motor winding. Results show that the planar jet heat transfer coefficients over a small (12.7-mm-diameter) target surface are not too much lower than for the circular orifice jet in which all of the ATF from the jet impinges on the target surface. The planar jet has the potential to achieve higher heat transfer over a larger area of the motor end winding. A new test apparatus was constructed to measure the spatial dependence of the heat transfer relative to the jet nozzle over a larger area representative of a motor end-winding. The tested planar flow geometry has the potential to provide more uniform cooling over the full end-winding surface versus the conventional jet configuration. The data will be used by motor designers to develop thermal management strategies to improve motor power density. Work on passive thermal design in collaboration with Oak Ridge National Laboratory to measure the thermal conductivity of wire bundle samples representative of end-winding and slot-winding materials was completed. Multiple measurement techniques were compared to determine which was most suitable for measuring composite wire bundle samples. NREL used a steady-state thermal resistance technique to measure the direction-dependent thermal conductivity. The work supported new interactions with industry to test new materials and reduce passive-stack thermal resistance in motors, leading to motors with increased power density. NREL collaborated with Ames Laboratory in the area of material characterization. The work focused on measuring the transverse rupture strength of new magnet materials developed at Ames. The impact of the improved transverse rupture strength is a mechanically stronger magnet that is easier for manufacturers to implement into motor designs. The thermal conductivity of the new magnet materials was also measured in comparison to two commercially available AlNiCo magnet materials. The impact of the thermal conductivity of the magnet material will need to be analyzed in the context of a motor application.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Observation of the nonlinear Hall effect under time-reversal-symmetric conditions

The electrical Hall effect is the production, upon the application of an electric field, of a transverse voltage under an out-of-plane magnetic field. Studies of the Hall effect have led to important breakthroughs, including the discoveries of Berry curvature and topological Chern invariants1,2. The internal magnetization of magnets means that the electrical Hall effect can occur in the absence of an external magnetic field2; this ‘anomalous’ Hall effect is important for the study of quantum magnets2,3,4,5,6,7. The electrical Hall effect has rarely been studied in non-magnetic materials without external magnetic fields, owing to the constraint of time-reversal symmetry. However, only in the linear response regime—when the Hall voltage is linearly proportional to the external electric field—does the Hall effect identically vanish as a result of time-reversal symmetry; the Hall effect in the nonlinear response regime is not subject to such symmetry constraints8,9,10. Here we report observations of the nonlinear Hall effect10 in electrical transport in bilayers of the non-magnetic quantum material WTe2 under time-reversal-symmetric conditions. We show that an electric current in bilayer WTe2 leads to a nonlinear Hall voltage in the absence of a magnetic field. The properties of this nonlinear Hall effect are distinct from those of the anomalous Hall effect in metals: the nonlinear Hall effect results in a quadratic, rather than linear, current–voltage characteristic and, in contrast to the anomalous Hall effect, the nonlinear Hall effect results in a much larger transverse than longitudinal voltage response, leading to a nonlinear Hall angle (the angle between the total voltage response and the applied electric field) of nearly 90 degrees. We further show that the nonlinear Hall effect provides a direct measure of the dipole moment10 of the Berry curvature, which arises from layer-polarized Dirac fermions in bilayer WTe2. Our results demonstrate a new type of Hall effect and provide a way of detecting Berry curvature in non-magnetic quantum materials.

solar (photovoltaic), solid state lighting, photos↗
DOE OSTI2023

Sourcing, Refining and Recycling of Rare-Earth Magnets

Permanent magnets today are used in a wide range of transportation, industrial, residential/commercial, consumer electronics, defense, domestic, data storage, wind energy, and medical markets and applications. There are five classes of commercial permanent magnet materials; however, magnets based on Nd-Fe-B account for over 60% of the global magnet production by value. They typically contain around 31 wt.% of rare earth elements (REEs), principally, Nd and Pr, plus Dy for higher-temperature performance. Nd-Fe-B magnets are forecast to grow throughout this decade, largely driven by the growth in electric vehicles of all types. However, several studies forecast a shortfall of the primary REEs from mined resources. In this paper, the sourcing, processing, and recycling of REEs are discussed. Additionally, presented are the advantages and disadvantages of the major recovery and recycling technologies for REEs.

36 MATERIALS SCIENCE↗