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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Analysis of Design Alternatives of Actively Cooled RF Window for MPEX

The Materials Plasma Exposure eXperiment (MPEX) has been designed as a linear plasma divertor simulator in order to address plasma material interaction (PMI) science for next-generation fusion devices. It will have the capability to test neutron irradiated samples with plasma fluxes of greater than 10 24 m -2 s -1 . It is expected to operate steady state for up to 10 6 s to consider PMI affects through reactor end of life. The conceptual design of MPEX was completed in 2019, with preliminary design having begun in 2020. The plasma source for MPEX is a helicon antenna, where the energized helical antenna sits outside of the vacuum in order to minimize impurities in the plasma. It is expected to receive up to 200 kW of continuous power, and so the antenna and the window must be actively cooled. The water-cooled copper antenna has been operated at full power on the Proto-MPEX device (which is a test facility to demonstrate the plasma source and heating systems). The water-cooled window, however, is a novel component that must meet numerous competing requirements. It requires a low dielectric loss to allow the Radio Frequency (RF) power to create the plasma within the vacuum boundary. It must be structurally robust to handle the significant heat flux from the plasma and any heat from dielectric coupling. It must be compatible with the coolant (preferably water). It requires a vacuum seal that minimizes impurities into the plasma and does not compromise the structural integrity of the window. Two window designs have been tested. Results from these tests, where temperatures are measured and heat fluxes inferred from infrared camera data, have been correlated with thermal-structural simulations. When these simulations are extrapolated to the full power steady-state heat fluxes that are expected in MPEX, the designs do not appear to have the necessary structural robustness. This study explores design alternatives for the MPEX helicon antenna window, presents analysis results for several of the alternatives, and shows a viable solution that satisfies the requirements for MPEX operation.

Tipton Jr, Joseph↗
DOE OSTI2021

First neutral beam experiments on Wendelstein 7-X

In the previous divertor campaign, the Wendelstein 7-X (W7-X) device injected 3.6 MW of neutral beam heating power allowing for the achievement of densities approaching 2 × 10 20 m -3 , and providing the first initial assessment of fast ion confinement in a drift optimized stellarator. The neutral beam injection (NBI) system on W7-X is comprised of two beam boxes with space for four radio frequency sources each. The 3.6 MW of heating reported in this work was achieved with two sources in the NI21 beam box. The effect of combined electron-cyclotron resonance heating (ECRH) and NBI was explored through a series of discharges varying both NBI and ECRH power. Discharges without ECRH saw a linear increase in the line-integrated plasma density, and strong peaking of the core density, over the discharge duration. The presence of 1 MW of ECRH power was found to be sufficient to control a continuous density rise during NBI operation. Simulations of fast ion wall loads were found to be consistent with experimental infrared camera images during operation. In general, NBI discharges were free from the presence of fast ion induced Alfvénic activity, consistent with low beam betas. These experiments provide data for future scenario development and initial assessment of fast-ion confinement in W7-X, a key topic of the project.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Investigating the quaternary structure of a homomultimeric catechol 1,2-dioxygenase: An integrative structural biology study

The structural analysis of catechol 1,2 dioxygenase from Stutzerimonas frequens GOM2, SfC12DO, was conducted using various structural techniques. SEC-SAXS experiments revealed that SfC12DO, after lyophilization and reconstitution processes, can form multiple enzymatically active oligomers, including dimers, tetramers, and octamers. These findings differ from previous studies, which reported active dimers in homologous counterparts with available crystallographic structures, or trimers observed exclusively in solution for SfC12DO and its homologous isoA C12DO from Acinetobacter radioresistens under low ionic strength conditions. In some cases, tetramers were also reported, such as for the Rodococcus erythropolis C12DO. The combined results of Small-Angle X-ray Scattering, Dynamic Light Scattering, and Transmission Electron Microscopy experiments provided additional insights into these active oligomers’ shape and molecular organization in an aqueous solution. These results highlight the oligomeric structural plasticity of SfC12DO, proving that it can exist in different oligomeric forms depending on the physicochemical characteristics of the solutions in which the experiments were performed. Remarkably, regardless of its oligomeric state, SfC12DO maintains its enzymatic activity even after prior lyophilization. All these characteristics make SfC12DO a putative candidate for bioremediation applications in polluted soils or waters.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Dairy manure acidogenic fermentation at hyperthermophilic temperature enabled superior activity of thermostable hydrolytic enzymes linked to the genus Caldicoprobacter

In this study, fermentation experiments were conducted under mesophilic, thermophilic, and hyperthermophilic conditions to investigate adaptation of microbial communities and its effect on extracellular enzyme activities toward degradation of cellulose, hemicellulose and proteins in dairy manure. Here, hyperthermophilic conditions transformed the microbiome structure and stimulated activity of extracellular proteolytic, cellulolytic, and hemicellulolytic enzymes. Specifically, the activities of protease, cellulose 1,4-β-cellobiosidase, and β-glucosidase secreted by hyperthermophilic microbes were higher by 22%, 47% and 49% compared to those produced by mesophilic and thermophilic communities. Enhanced hydrolytic activity of hyperthermophilic microbes enabled improved feedstock solubilization and production of 39% and 22% more soluble COD than mesophilic and thermophilic microbes, respectively. Connections between hydrolytic function and microbial community structure at various temperatures were assessed using the PICRUSt2 computational tool. Genus Caldicoprobacter was identified as the primary candidate responsible for increased production of thermostable endo-1,4-β-glucanase, β-glucosidase and endo-1,4-β-xylanase, and enhanced hydrolytic performance of hyperthermophilic microbial community.

09 BIOMASS FUELS↗
DOE OSTI2021

The Large Enriched Germanium Experiment for Neutrinoless ββ Decay (LEGEND-1000 Preconceptual Design Report)

We propose the construction of LEGEND-1000, the ton-scale Large Enriched Germanium Experiment for Neutrinoless ββ Decay. This experiment is an international project designed to answer one of the highest priority questions in fundamental physics. It consists of 1000 kg of Ge detectors enriched to more than 90% in the 76 Ge isotope of interest operated in a liquid argon active shield at a deep underground lab. The experiment is designed to achieve a discovery potential that covers the inverted-ordering neutrino mass scale region. The baseline design assumes installation in the SNOLAB cryopit. A similar experimental setup could also be realized at the LNGS alternative site.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

A Comprehensive Investigation of Active Learning Strategies for Conducting Anti-Cancer Drug Screening

It is well-known that cancers of the same histology type can respond differently to a treatment. Thus, computational drug response prediction is of paramount importance for both preclinical drug screening studies and clinical treatment design. To build drug response prediction models, treatment response data need to be generated through screening experiments and used as input to train the prediction models. In this study, we investigate various active learning strategies of selecting experiments to generate response data for the purposes of (1) improving the performance of drug response prediction models built on the data and (2) identifying effective treatments. Here, we focus on constructing drug-specific response prediction models for cancer cell lines. Various approaches have been designed and applied to select cell lines for screening, including a random, greedy, uncertainty, diversity, combination of greedy and uncertainty, sampling-based hybrid, and iteration-based hybrid approach. All of these approaches are evaluated and compared using two criteria: (1) the number of identified hits that are selected experiments validated to be responsive, and (2) the performance of the response prediction model trained on the data of selected experiments. The analysis was conducted for 57 drugs and the results show a significant improvement on identifying hits using active learning approaches compared with the random and greedy sampling method. Active learning approaches also show an improvement on response prediction performance for some of the drugs and analysis runs compared with the greedy sampling method.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Dipolar Heteronuclear Correlation Solid-State NMR Experiments between Half-Integer Quadrupolar Nuclei: The Case of 11 B– 17 O

With 73% of all NMR-active nuclei being quadrupolar, there is great interest in the development of NMR experiments that can probe the proximity of quadrupolar spins. Here, pulse sequences for magic-angle spinning (MAS) 11 B– 17 O resonance-echo saturation-pulse double-resonance (RESPDOR) and dipolar heteronuclear multiple quantum correlation (D-HMQC) solid-state NMR experiments were investigated. In these pulse sequences, rotational-echo double-resonance (REDOR) recoupling was used with central transition (CT)-selective π-pulses applied to either the 11 B or 17 O spins to recouple 11 B– 17 O dipolar interactions. 11 B{ 17 O} RESPDOR experiments on 17 O-enriched boric acid and benzene diboronic acid showed that application of dipolar recoupling on the 11 B channel yielded more signal dephasing than when recoupling is applied on the 17 O channel; however, short effective 11 B transverse relaxation time constants (T 2 ') hinder the acquisition of dephasing curves out to long recoupling durations. Application of REDOR recoupling to 17 O spins was found to produce significant dephasing without compromising the 11 B T 2 '. Comparison of experimental 11 B{ 17 O} RESPDOR curves to those of numerical simulations enabled the 17 O isotopic enrichment to be estimated. 2D 11 B{ 17 O} D-HMQC spectra were recorded with either 11 B or 17 O REDOR recoupling under a variety of radio frequency field conditions. Lastly, 2D 11 B{ 17 O} and 23 Na{ 17 O} D-HMQC spectra of an 17 O-enriched sodium borate glass were acquired to demonstrate the practical application of these heteronuclear correlation experiments to probe structural connectivity between two quadrupolar spins. Importantly, the high-field 2D 11 B– 17 O D-HMQC NMR spectrum revealed two unique 17 O sites correlating to 4-coordinate BO 4 ( [4] B), which were attributed to the [3] B–O– [4] B and [4] B–O– [4] B bridging O atoms. Furthermore, the heteronuclear correlation experiments outlined here should be applicable to a variety of quadrupolar spin pairs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Effects of experimental and seasonal drying on soil microbial biomass and nutrient cycling in four lowland tropical forests

Changes in precipitation represent a major effect of climate change on tropical forests, which contain some of the earth’s largest terrestrial carbon (C) stocks. Such changes are expected to influence microbes, nutrients, and the fate of C in tropical forest soils. To explore this, we assessed soil microbial biomass, potential extracellular enzyme activities, and nutrient availability in a partial throughfall exclusion experiment in four seasonal lowland tropical humid forests in Panama with wide variation in precipitation and soil fertility. We hypothesized that throughfall exclusion would reduce microbial biomass and activity and accentuate dry season soil nutrient accumulation, with larger effects in wetter, less droughtresistant forests. We observed a baseline seasonal pattern of decreased microbial biomass and increased extractable dissolved organic C (DOC), total dissolved nitrogen (TDN), nitrate (NO 3 – ), and resinextractable phosphorus (P) in the dry season, with the strongest patterns for nitrogen (N). However, potential enzyme activities showed no consistent seasonality. In line with seasonal drying, throughfall exclusion decreased soil microbial biomass in the wet season and increased TDN and NO 3 – , especially in the dry season. In contrast to seasonal drying, throughfall exclusion decreased DOC and did not affect resinextractable P, but slightly decreased potential phosphatase activities. Potential enzyme activities varied among sites and sampling times, but did not explain much variation in microbial biomass or substrate availability. We conclude that reduced rainfall in tropical forests might accentuate some dry season patterns, like reductions in microbial biomass and accumulation of extractable nutrients. However, our data also suggest new patterns, like reduced inputs of DOC to soils with drying, which could have cascading effects on soil ecological function and C storage.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Activity Estimations for HSA Co-60 targets for Cycles 168A, 168B, and 169A Memo

67 HSA cobalt targets have been irradiated in the ATR, starting back on 2/10/15. Individual HSA cobalt targets may have been moved to different positions and irradiated at different times in the ATR. A tool called the Isotope Production and Activation tool (IPA tool) was developed to capture the changes for different irradiation conditions. The IPA tool uses cross section and flux data, cycle history data, and HSA experiment positioning data to estimate a range of specific activities for each of the HSA cobalt targets to generate SCALE/ORIGENS inputs for each target. The IPA tool also post-processes the results for use in tables and figures. The IPA tool derived results that can be independently verified using an acceptable alternative method. The memo contains the specific activity for all 67 HSA cobalt targets.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Determining the 9 $\mathrm{Be}$($n, γ$) 10 $\mathrm{Be}$ integral cross section at fission neutron energies

The 9 B neutron capture cross section has significant implications for Be materials in the nuclear industry as well as the α process in stellar nucleosynthesis. While the cross section is well constrained at thermal neutron energies, there is a lack of experimental data at higher neutron energies, and the evaluated nuclear data libraries can differ by up to two orders of magnitude. We calculate the 9 Be(n, γ) 10 Be integral cross section at fission neutron energies in an effort to resolve disagreements amongst the nuclear data libraries. Foil irradiation experiments were performed using the Flattop critical assembly at the National Criticality Experiments Research Center with either the highly enriched U or Pu cores, with target foil stacks placed at multiple locations to exploit different neutron energy profiles. Accelerator mass spectrometry was used to measure the 10 Be/ 9 Be ratio in irradiated Be foils, while all other activation products were quantified through gamma spectrometry. The experiments were simulated using the Monte Carlo N-Particle radiation transport code and combined with experimental results to determine the total neutron fluence, while the staysl-pnnl suite and fispact-ii code were used to validate the model and assess the systematic uncertainty. The new 9 Be(n, γ) 10 Be integral cross sections calculated in this work are 26.5 ± 2.2µb at 0.59 ± 0.07 MeV, 24 ± 3 µb at 0.98 ± 0.14 MeV, 21.7 ± 1.3 µb at 1.26 ± 0.11 MeV, 21.8 ± 1.4 µb at 1.32 ± 0.11 MeV, and 18.6 ± 1.1 µb at 1.46 ± 0.13 MeV. These results do not agree with integral cross sections from any of the nuclear data library evaluations. Discrepancies between the new integral cross sections reported here and the nuclear data libraries suggest a more complex cross-section structure in the MeV range which allows for more resonance contributions, and more work is needed to further constrain the evaluated cross sections.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2025

Selective semihydrogenation of acetylene in ethylene using defect-rich boron nitride catalyst from flux reconstruction

Efficient removal of trace acetylene from ethylene streams is essential for producing polymer-grade ethylene, yet achieving highly selective semihydrogenation without over-hydrogenation remains a long-standing challenge. A key barrier is the lack of a simple, low-cost catalyst that can activate hydrogen effectively while preventing ethylene from reacting further. Here we show that defect-rich boron nitride, prepared through a straightforward flux reconstruction method, serves as a highly selective and metal-free catalyst for acetylene semihydrogenation. The catalyst contains abundant open boron and nitrogen sites that enable efficient hydrogen activation and rapid release of ethylene, thereby avoiding over-hydrogenation. Experiments combined with isotope labeling and theoretical analysis reveal that these defects lower the energy barrier for hydrogen activation while accelerating product desorption. Our findings demonstrate a scalable strategy for defect engineering in boron nitride and highlight its potential as a robust, sustainable alternative to metal-based catalysts in industrial ethylene purification.

Wang, Tao [Oak Ridge National Laboratory (ORNL), O↗
DOE OSTI2022

Investigating the impact of micropore volume of aminosilica functionalized SBA-15 on catalytic activity for amine-catalyzed reactions

Mesoporous materials such as SBA-15 are used in many applications since the materials are robust and have tunable properties. Whereas these materials are thought to be ideal, the materials are complex with the common synthesis methods producing materials that contain micropores. This work will investigate the impact of micropores on catalytic activity of aminosilica materials. For comparison, materials are formed using a standard method that produces materials with micropores (REG-SBA-15) and using a modified method that produces materials with negligible micropore volume (NMP-SBA-15). After grafting the calcined support with an aminosilane (either (N-methyl amino propyl) trimethoxy silane (denoted as 2°Am) or (N,N-diethyl-3-amino propyl) trimethoxy silane (3°Am)), catalytic testing experiments reveal that NMP-SBA-15 functionalized materials are more active than REG-SBA-15 functionalized materials for a range of reactions. The reactions include (a) glucose isomerization where amines interacting with surface silanols limit catalytic activity and (b) aldol and Knoevenagel chemistry where amine-silanol interactions increase the reaction rate. For aldol chemistry, the observed difference in rate is further investigated using site quantification experiments. Interestingly, the results reveal that three types of sites exist for each material, including sites that are (1) highly active, (2) intermediate active, and (3) inactive. Additionally, NMR experiments indicate that amines immobilized on REG-SBA-15 supports are less mobile than amines on NMP-SBA-15. For REG-SBA-15, the materials are found to have aminosilanes that have limited mobility and the largest fraction of inactive sites, which suggests that the inactive catalytic sites are in the micropores. Overall, the design of highly active catalytic materials can be achieved using materials that have limited micropore volumes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Study of alkaline carbonate cooling to mitigate Ex-Vessel molten corium accidents

To mitigate adverse effects from molten corium following a reactor pressure vessel failure (RPVF), some new reactor designs employ a core catcher and a sacrificial material (SM), such as ceramic or concrete, to stabilize the molten corium and avoid containment breach. Existing reactors cannot easily be modified to include these SMs but could be modified to allow injectable cooling materials. Current reactor designs are limited to using water to stabilize the corium, but this can create other issues such as reaction of water with the concrete forming hydrogen gas. Here the novel SM proposed is a granular carbonate mineral that can be used in existing light water reactor plants. The granular carbonate will decompose when exposed to heat, inducing an endothermic reaction to quickly solidify the corium in place and producing a mineral oxide and carbon dioxide. Corium spreading is a complex process strongly influenced by coupled chemical reactions, including decay heat from the corium, phase change, and reactions between the concrete containment and available water. A recently completed Sandia National Laboratories laboratory directed research and development (LDRD) project focused on two research areas: experiments to demonstrate the feasibility of the novel SM concept, and modeling activities to determine the potential applications of the concept to actual nuclear plants. Small-scale experiments using lead oxide (PbO) as a surrogate for molten corium demonstrate that the reaction of the SM with molten PbO results in a fast solidification of the melt due to the endothermic carbonate decomposition reaction and the formation of open pore structures in the solidified PbO from CO 2 released during the decomposition. A simplified carbonate decomposition model was developed to predict thermal decomposition of carbonate mineral in contact with corium. This model was incorporated into MELCOR, a severe accident nuclear reactor code. A full-plant MELCOR simulation suggests that by the introduction of SM to the reactor cavity prior to RPVF ex-vessel accident progression, e.g., core-concrete interaction and core spreading on the containment floor, could be delayed by at least 15 h; this may be enough for additional accident management to be implemented to alleviate the situation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

MRP and NEAMS Meeting - Current Modeling to Support Experiments

Heat-pipe cooled micro-reactor is currently being actively investigated in the NS&T department at INL. Given the high operation temperature and large temperature gradients in the system, the induced thermal stresses need to be well analyzed and kept within the safety margin. Two commercial FEM software (ABAQUS and STAR-CCM+) have been proposed to simulate and compare for both the temperature and stress distributions for the single heat pipe experiments, with the middle single heat pipe and 6 heaters surrounded. This presentation file is aimed to provide the latest updates for the researchers who is under NEAMS program and involved with the DOE micro-reactor program

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Thermal Activation of Zirconium(IV) Acetylacetonate Catalysts to Enhance Polyurethane Synthesis and Reprocessing

Carbamate formation and exchange catalysts enable efficient polyurethane (PU) manufacturing, as well as emerging recycling and reprocessing methods for PU thermosets. Zirconium β-diketonate complexes, such as Zr acetylacetonate [Zr(acac) 4 ], are effective alternatives to toxic organotin catalysts that have been used for PU reprocessing. Here, we report that Zr(acac) 4 undergoes a thermally activated process in the PU network during reprocessing that transforms it into a more active carbamate exchange catalyst. This process is associated with the irreversible loss of acetylacetonate ligands and is not observed for the more sterically hindered Zr 2,2,6,6-tetramethyl-3,5-heptanedione [Zr(tmhd) 4 ] complex. Crossover experiments between PU thermoplastics indicated enhanced carbamate exchange after the thermal activation of Zr(acac) 4 in the presence of one of the PUs, whereas a sample of Zr(acac) 4 activated in the absence of the PU had no catalytic activity. Thermal gravimetric analysis suggested that this process is associated with the loss of one protonated acac ligand. Stress relaxation analysis of PU thermosets indicated a distinct change in the characteristic relaxation time associated with the thermal activation of Zr(acac) 4 at temperatures above 140 °C; no such change was observed for samples reprocessed using Zr(tmhd) 4 . Density functional theory and molecular experiments suggest that irreversible ligand exchange of acac with alkoxide or carbamate reduces the activation energy for urethane formation and reversion. Furthermore, the Zr(acac) 4 catalyst activated in the presence of a PU’s polyol precursor provided more porous and less dense PU foams compared to those made using the unactivated Zr(acac) 4 catalyst. Furthermore, these findings are important for developing improved PU synthesis and recycling processes. Thermally activating a catalyst during reprocessing may provide more nuanced control of the in-use and reprocessing characteristics of PU thermosets.

Alcohols↗
DOE OSTI2020

Determining Multi-Component Phase Diagrams with Desired Characteristics Using Active Learning

Herein, we demonstrate how to predict and experimentally validate phase diagrams for multi-component systems from a high-dimensional virtual space of all possible phase diagrams involving several elements based on small existing experimental data. The experimental data for bulk phases for known systems represents a sampling from this space, and screening the space allows multi-component phase diagrams with given design criteria to be built. This approach uses machine learning methods to predict phase diagrams and Bayesian experimental design to minimize experiments for refinement and validation, all within an active learning loop. The approach is proven by predicting and synthesizing the ferroelectric ceramic system (1-ω)(Ba 0.61 Ca 0.28 Sr 0.11 TiO 3 )-ω(BaTi 0.888 Zr 0.0616 Sn 0.0028 Hf 0.0476 O 3 ) with a relatively high transition temperature and triple point, as well as the NiTi-based pseudo-binary phase diagram (1-ω)(Ti 0.309 Ni 0.485 Hf 0.20 Zr 0.006 )-ω(Ti 0.309 Ni 0.485 Hf 0.07 Zr 0.068 Nb 0.068 ) designed for high transition temperature (ω ≤ 1). Each phase diagram is validated and optimized through only three new experiments. The complexity of these compounds is beyond the reach of today’s computational methods.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Proton-Responsive Ligands Promote CO 2 Capture and Accelerate Catalytic CO 2 /HCO 2 – Interconversion

The synthesis and investigation of [Rh(DHMPE) 2 ][BF 4 ] (1) are reported. 1 features proton-responsive 1,2-bis[(dihydroxymethyl)phosphino]ethane (DHMPE) ligands, which readily capture CO 2 from atmospheric sources upon deprotonation. The protonation state of the DHMPE ligand was observed to have a significant impact on the catalytic reactivity of 1 with CO 2 . Deprotonation and CO 2 binding to 1 result in a ∼10-fold rate enhancement in catalytic degenerate CO 2 reduction with formate, monitored by 12 C/ 13 C isotope exchange between H 12 CO 2 – and 13 CO 2 . Studies performed using a similar complex lacking the hydroxyl ligand functionality ([Rh(DEPE) 2 ][BF 4 ] where DEPE = 1,2-bis(diethylphosphino)ethane) do not show the same rate enhancements when base is added. Based upon the cation-dependent activity of the catalyst, Eyring analysis, and cation sequestration experiments, CO 2 binding to 1 is proposed to facilitate preorganization of formate/CO 2 in the transition state via ligand-based encapsulation of Na + or K + cations to lower the activation energy and increase the observed catalytic rate. Incorporation of proton-responsive DHMPE ligands provides a unique approach to accelerate the kinetics of catalytic CO 2 reduction to formate.

Anions↗
DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗