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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Final design and first use of in-situ measuring apparatus for measurement of permanent magnet resiliency in CEBAF’s radiation environment

In this work we outline the final design and initial measurement lessons for the holders and measuring apparatus of the permanent magnet resiliency experiment which is a part of the FFA@CEBAF proposed upgrade. The experiment will expose permanent magnets to the radiation environment of CEBAF. Due to safety regulations we need to measure the magnets in the tunnel without bringing them out, so we designed a mobile measuring system as well as a series of protocols to allow us to speedily measure these samples even under adverse conditions. We also designed our system to be capable of taking measurements even with component failures.

Accelerator Physics↗
DOE OSTI2025

Modeling and design of compact, permanent-magnet transport systems for highly divergent, broad energy spread laser-driven proton beams

Laser-driven (LD) ion acceleration has been explored in a newly constructed short focal length laser beamline at the BELLA petawatt facility (interaction point 2, iP2). For applications utilizing such LD ion beams, a beam transport system is required, which for reasons of compactness be ideally contained within 3 m. While they are generated from a micron-scale source, large divergence and energy spread of LD ion beams present a unique challenge to transporting them compared to beams from conventional accelerators. This study gives an overview of proposed compact transport designs using permanent magnets satisfying different requirements depending on the application for the iP2 laser beamline such as radiation biology, material science, and high-energy density science. These designs are optimized for different parameters such as energy spread and peak proton density according to the application’s need. The various designs consist solely of permanent magnet elements, which can provide high magnetic field gradients on a small footprint. While the field strengths are fixed, we have shown that the beam size is able to be tuned effectively by varying the placement of the magnets. The performance of each design was evaluated based on high-order particle tracking simulations of typical LD proton beams. We also examine the ability of certain configurations to tune and select beam energies, critical for specific applications. A more detailed investigation was carried out for a design to deliver 10 MeV LD accelerated ions for radiation biology applications. With these transport system designs, the iP2 laser beamline is ready to house various application experiments.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Demagnetization analysis of an 18 GHz electron cyclotron resonance ion source permanent magnet hexapole

An upgrade of ECR2 at the Argonne Tandem Linac Accelerator System is under way, focusing on increasing the intensity capabilities of the facility. ECR2 is a room temperature electron cyclotron resonance ion source, and the upgrade has strict requirements to retain radial access to the plasma chamber and keep the ion source operating without the use of superconducting magnets. The upgrade design with respect to the magnet arrangement and magnetization vectors has recently been presented [R. C. Vondrasek, J. McLain, and R. H. Scott, J. Phys.: Conf. Ser. 2743 , 012044 (2024)] using the same magnetic material as the current ECR2 hexapole. A thorough exploration of the demagnetization potential of this hexapole was carried out, and the risk of demagnetization was deemed too high, despite the magnetic performance meeting the requirements for the upgrade. Additional permanent magnet materials are considered with their respective performance evaluated. Magnet strength and demagnetization resistance are investigated and optimized with the final room temperature design demonstrating a high temperature transient demagnetization resistance and a radial magnetic field of 1.18 T at the plasma chamber wall. Finally, the simulations of this hexapole suggest that it will be sufficient to optimize intensity with a 14.5 GHz driving frequency and will allow 18 GHz operation, while keeping a high safety margin for maintaining magnet performance.

Argonne Tandem Linac Accelerator System↗
DOE OSTI2025

Jump-Start U.S. Manufacturing of High-Performance Permanent Magnets

Gas atomized feedstock powders for Nd-Fe-B based magnets are more robust and cost effective than the strip-cast sheet currently used as feedstock for milling by the magnet industry. However, gas atomized powder’s crystallinity and grain boundary phases are less ideal than the strip cast flake. We proposed to optimize the atomization process as well as the powder chemistry to address this issue and to eliminate heavy rare earth elements from these magnet alloys. Our goal is to help GKN-Hoeganaes, a US metal powder company, who used to make Nd-Fe-B magnets, to bring back US manufacturing of these high energy density permanent magnets.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Solenoidal Fields from Permanent Magnets for a Polarized Electron Preinjector

This technical note describes the design of a compact focusing solenoid constructed from permanent bar magnets, intended for the low-energy section of a spin-polarized electron injector. Typically, quadrupole triplets provide appropriate focusing for the low-energy spin rotator section; however, their large footprint precludes the insertion of sufficient beam diagnostics. The primary motivation of this study is to provide beam focusing while preserving the vertical spin orientation of the electron beam. We propose a solenoidal field composed of multiple permanent magnets arranged to naturally yield a zero longitudinal magnetic field integral ($\int B_zdz = 0$). This design serves as a compact, passive, and non-coupling alternative to traditional quadrupole triplets. We present the magnet arrangement, field calculation methodology, spin tracking simulations using space charge codes, and calculations demonstrating that the required field strength is achievable.

43 PARTICLE ACCELERATORS↗
NASA NTRS1965

Frictionless Bearing Uses Permanent Magnets

The purpose of this innovation was to develop a frictionless bearing for high speed, light load applications. The device involves the incorporation of permanent magnets in the bearing design. The repulsion of like magnetic poles provides concentric support of the inner member so that no metallic contact occurs between the bearing surfaces.

Source record↗
DOE OSTI2025

Extended State Observer-Based Robust Model Predictive Velocity Control for Permanent Magnet Synchronous Motor

This article proposes an extended state observer based robust model predictive velocity control to decrease system prediction error under parameter uncertainties for permanent magnet synchronous motor (PMSM). We develop a new PMSM model that consists of velocity and acceleration to lump the system information and an external disturbance into a disturbance. The extended state observer (ESO) is designed to estimate the velocity, acceleration, and disturbance. By estimating the state variables and disturbance using the ESO, the model predictive control (MPC) finds the optimal control input by predicting future system behavior. Additionally, the direct current controller is designed so that the direct current converges to zero. Because the proposed method is not designed based on the cascade structure from the viewpoint of velocity control, the optimization control for the velocity and currents can be defined. Thus, the proposed method is robust against external disturbances and parameter uncertainties owing to feedback linearization, state feedback, and ESO-based MPC using the acceleration PMSM model. The proposed control algorithm was experimentally verified and it showed improved velocity tracking performance compared with ESO-based MPC using the conventional PMSM model.

42 ENGINEERING↗
DOE OSTI2025

Assessment of errors in analytic modeling of permanent magnet electron spectrometers for laser-plasma accelerators

Here, we assess the error in three treatments of a critical electron beam diagnostic for laser-plasma acceleration (LPA) experiments: a permanent magnet electron spectrometer. Since LPA electron spectrometers are often difficult to calibrate due to the scarcity of well-characterized, tunable electron beam sources in the appropriate energy range and the mechanical complexity of electron spectrometers, the standard of calibration is Hall probe measurements. We first compare the electron spectrometer performance between SIMION calculations and the Hall probe measurements. We find up to a 60% (<8%) error in determining the absolute energy for electrons below (above) 80 MeV when using the SIMION-modeled magnetic field vs the measured magnetic field due to SIMION overpredicting fringe field strength. The difference in spectrometer energy resolution is within ∼10% between the modeled and measured fields. We then assess a simple block model, which is commonly used. We find that the simple block model presented here sufficiently captures the predicted as-built spectrometer performance for any application provided that the user can tolerate uncertainties on absolute energy determination up to 5% and errors on energy resolution up to 1%.

Electromagnetic optics↗
DOE OSTI2026

Design and optimization of processes for recovering rare earth elements from end‐of‐life permanent magnets

Recovery of rare earth elements (REEs) from end-of-life (EOL) products represents a strategic opportunity to strengthen the domestic supply chain for rare earth elements. This work presents a superstructure-based optimization framework for finding the most economical processing pathway for different EOL rare earth permanent magnets (REPMs). The framework evaluates state-of-the-art technologies across four processing stages—disassembly, demagnetization, leaching and extraction, and precipitation and calcination—using net present value (NPV) maximization and cost of recovery (COR) minimization objectives. A novel bottom-up costing framework for hydrogen decrepitation is also introduced. Two feedstocks were considered: REPMs from EOL hard disk drives (HDDs), and electric and hybrid electric vehicles (EVs and HEVs). While HDD recycling proved unprofitable due to limited feedstock availability, EVs/HEVs were profitable across a range of parameters and cost estimates. Therefore, our findings suggest that the proposed EOL EV/HEV recycling process may be economical and is worthy of further investigation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Injection, confinement, and diagnosis of electrons and positrons in a permanent magnet dipole trap

Abstract Prerequisites for the goal of studying long-lived, magnetically confined, electron–positron pair plasmas in the laboratory include the injection of both species into the trap, long trapping times, and suitable diagnostic methods. Here we report recent progress on these tasks achieved in a simple dipole trap based on a supported permanent magnet. For the injection of electrons, both an $$\textbf{E}\times B$$ E × B drift technique (of a $$\sim $$ ∼ 2– $$\upmu $$ μ A, 6-eV beam) and “edge injection” (from a filament emitting a few mA and biased to some tens of volts) have been demonstrated; the former is suitable for low-density beams with smaller spatial and velocity spreads, while the latter employs fluctuations arising from collective behavior. To diagnose the edge-injected electrons, image potentials and currents induced on a wall probe, the magnet case, and wall electrodes were measured. Confinement of drift-injected positrons, measured experimentally, exhibited at least two well-separated timescales. Simulations reproduced this qualitatively, using a simple model of elastic collisions with residual background gas, and point to small adjustments for increasing trapping times. In a major upgrade to diagnostic capabilities, 25 bismuth germanate detectors, placed in three reentrant ports, are able to localize annihilation gammas, which will be used in future experiments to distinguish between different loss channels. Graphical abstract

von der Linden, J. (ORCID:0000000327477813)↗
DOE OSTI2026

Separation and Recovery of High-Purity Dysprosium from Electric Vehicle Scrap Permanent Magnets Using Cyanex 572, a Cationic Extractant in a Membrane Solvent Extraction Process

Rare earth elements (REEs), especially heavy rare earth elements such as dysprosium (Dy), have gained immense attention globally due to their widespread use in many state-of-the-art technologies. Consequently, demand for REEs is increasing rapidly in comparison to their supply. Recycling of REEs from end-of-life (EoL) electronic waste (e-waste) can help to mitigate the increasing gap between the demand and supply of REEs. This study reports the separation and recovery of high-purity Dy from various feedstocks such as scrap permanent magnets (SPMs), electric vehicle (EV) magnets, and mixed rare earth oxides (REOs) using an economically viable and scalable membrane solvent extraction (MSX) process. First, the optimized conditions (organic phase composition and feed solution acid concentration) for the separation of Dy from light REEs such as neodymium (Nd) and praseodymium (Pr) were evaluated using liquid–liquid extraction. Thereafter, a multistage MSX process was developed to separate high purity (>99.5 wt %) Dy from Nd and Pr using Cyanex 572, a cationic extractant. Using feedstocks with varying initial compositions, the MSX process obtained 100% pure Dy with 63–96% Dy recovery in three to six stages with a maximum extraction rate of 2.9 g m–2 h –1 . Purity of the recovered Dy was confirmed via additional characterization such as scanning electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction. This novel MSX process holds immense potential for industry deployment for the separation of heavy and light rare REEs from a wide range of e-waste.

electrical vehicle magnets↗
DOE OSTI2025

Design and performance validation of a high-temperature downhole permanent magnet generator used for an electro-pulse boring system in geothermal energy applications

Novel, direct-energy drilling technologies such as electro-pulse boring, have the potential to significantly increase the speed and depth of geothermal drilling but have not achieved widespread adoption due to several economic and technical barriers. One major challenge is that these drilling systems require electric power downhole. The current practice is to supply power to the drill string components by running electric cables down the geothermal well, but at the targeted well depths, this practice is cost-inhibitive, inefficient in terms of power consumption, and adds an additional failure point with the long cabling going through a highly corrosive, high-temperature environment. A solution to this problem is to develop high-temperature electric generator technology that can generate the required power downhole. Such a generator must also operate with high efficiency at the target downhole ambient temperature of 250 °C. In this paper, we investigate the various design considerations for this concept and subsequently design the downhole electric generator using a multi-objective design optimization approach. Through electromagnetic-, thermal- and short-circuit fault condition analysis, it is demonstrated that the optimized downhole electric generator concept presented in this paper can meet the performance requirements within this extreme drilling environment. Most remarkably, it is shown that a generator efficiency of 90% is achieved. In conclusion, to validate the results presented in this paper, a prototype generator is built and its performance is measured at 250 °C using a test bench uniquely developed for this application.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Extrusion compression molded critical rare earth free bonded permanent magnets

Samarium iron nitride (Sm-Fe-N) bonded magnets have emerged as promising candidates for various industrial applications due to their exceptional magnetic properties. Compounds with magnetic material 95 wt fraction (wt.%) (∼74 vol%) and 97 wt.% (∼81 vol%) of SmFeN in a polyamide (PA12) polymer binder are manufactured using a batch mixer followed by compression molding. A maximum energy product ( BH ) max of 186.21 kJ.m -3 (23.4 MGOe) is achieved in the 95 wt.% bonded magnets; 97 wt.% magnets had a ( BH ) max of 165.52 kJ.m -3 (20.8 MGOe). It is found that the degree of alignment (DoA) of 99 % is achieved in the 95 wt.% magnets, whereas the 97 wt.% magnets are limited to a DoA of 90 % respectively. The high DoA can be attributed to low particle-particle interaction during the post-magnetic field alignment process. Finally, this research provides a useful insight of binder-particle interactions at very high magnet weight fractions and their effect on magnetic strength and performance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Spike-Free Adaptive Sliding Mode Control: Application to Permanent Magnet Synchronous Motors

A new methodology for adaptive sliding mode control (ASMC) has been widely used to improve the control performance in various systems. This method exhibits several advantages, including low sliding mode control (SMC) chattering, no knowledge of the system disturbance bound, and no overestimation of the control gain. Despite its advantages, this method can be hampered by the spike phenomenon, slow control gain convergence, and difficulty in achieving optimal performance under varying disturbances. Consequently, this article proposes a spike-free ASMC method with a disturbance observer (DOB) to address these problems. Previous ASMC methods have been analyzed via simulations to verify the aforementioned problems. Here, this analysis highlights the need for disturbance compensation and improvements in the SMC gain adaptation law. Therefore, a DOB is designed to mitigate the spike phenomenon by compensating for disturbances. Subsequently, an SMC gain adaptation law based on disturbance error estimation is designed to eliminate the spike phenomenon completely. The proposed adaptation law makes the SMC gain to converge to a slightly higher value than the disturbance estimation error. Consequently, the proposed method not only eliminates the spike phenomenon, but also ensures optimal performance under varying disturbances. The performance of the proposed method is experimen tally validated through a comparative study.

42 ENGINEERING↗