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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Rare‐Earth Reduction in High‐Speed PM‐Assisted Synchronous Reluctance Motors Using Hybrid Magnet Strategies and Design Optimisation for 800 V EVs

The trend towards electrifying transportation systems has stimulated research endeavours aimed at developing electric machines that are not only high speed and efficient but also low‐cost and compact. To support this transition, the US Department of Energy (DOE) has established ambitious targets of $7/kW cost and 12 kW/L power density for the electric drivetrains. This paper attempts to meet these targets by proposing high‐speed permanent magnet assisted synchronous reluctance machine (PMASynRM) topologies enabled by hybrid magnet strategies, combining rare‐earth (RE) magnets with low‐cost, RE‐free alternatives. Modified 2‐layer and 3‐layer U‐shaped rotor configurations, featuring structural reinforcements to withstand high mechanical stress at elevated speeds, are developed. A multi‐objective design optimisation framework is employed to optimise the rotor design, targeting reductions in RE magnet volume, magnet demagnetisation risk and torque ripple while achieving the desired electromagnetic performance. A comprehensive analysis of the optimised rotor designs, compared against a 16,000 rpm, 800 V baseline IPM motor, shows over 70% RE reduction, demagnetisation risk below 3.5% and torque ripple under 10%. Detailed analyses of performance trends across various magnet combinations and rotor configurations highlight the viability of hybrid magnet PMASynRM designs as cost‐effective, robust and energy‐efficient solutions for next‐generation EVs.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Plasma-based particle sources

High-brightness particle beams generated by advanced accelerator concepts have the potential to become an essential part of future accelerator technology. In particular, high-gradient accelerators can generate and rapidly accelerate particle beams to relativistic energies. The rapid acceleration and strong confining fields can minimize irreversible detrimental effects to the beam brightness that occur at low beam energies, such as emittance growth or pulse elongation caused by space charge forces. Due to the high accelerating gradients, these novel accelerators are also significantly more compact than conventional technology. Advanced accelerators can be extremely variable and are capable of generating particle beams with vastly different properties using the same driver and setup with only modest changes to the interaction parameters. So far, efforts have mainly been focused on the generation of electron beams, but there are concepts to extend the sources to generate spin-polarized electron beams or positron beams. The beam parameters of these particle sources are largely determined by the injection and subsequent acceleration processes. Although, over the last decade there has been significant progress, the sources are still lacking a sufficiently high 6-dimensional (D) phase-space density that includes small transverse emittance, small energy spread and high charge, and operation at high repetition rate. This is required for future particle colliders with a sufficiently high luminosity or for more near-term applications, such as enabling the operation of free-electron lasers (FELs) in the X-ray regime. Major research and development efforts are required to address these limitations in order to realize these approaches for a front-end injector for a future collider or next-generation light sources. In particular, this includes methods to control and manipulate the phase-space and spin degrees-of-freedom of ultrashort plasma-based electron bunches with high accuracy, and methods that increase efficiency and repetition rate. These efforts also include the development of high-resolution diagnostics, such as full 6D phase-space measurements, beam polarimetry and high-fidelity simulation tools. A further increase in beam luminosity can be achieve through emittance damping. Emittance cooling via the emission of synchrotron radiation using current technology requires kilometer-scale damping rings. For future colliders, the damping rings might be replaced by a substantially more compact plasma-based approach. Here, plasma wigglers with significantly stronger magnetic fields are used instead of permanent-magnet based wigglers to achieve similar damping performance but over a two orders of magnitude reduced length.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Magnetic Materials Research at SRNL

Introduction – What are Magnetic Materials? Magnetic materials are crystalline solids which below a certain temperature, known as the ordering temperature, display spontaneous order in their magnetic moments. Results • Enhanced thermal stability and saturation magnetization with Y substitution in Ce2Fe14B based permanent magnets • Discovered a new ferromagnetic phase transition at TC = 62.9 K in (Dy1/3Mo2/3)2AlC and validated the two previously reported low temperature magnetic phases Characterization of Magnetic Materials Raw high purity materials are melted together to synthesize a crystalline sample using an arc melter at Savannah River National Laboratory (SRNL). Use high energy ball milling to form a hard/soft magnetic composite using Y substituted Ce2Fe14B. Finish structural characterization on γ- irradiated (RE1/3Mo2/3)2AlC (RE = Rare Earth) MAX samples. Unit Cell Lattice Points

Bretana, Alex↗
NASA NTRS1972

Development, fabrication and testing of a magnetically connected plastic vacuum probe surface sampler

The sampler utilizes permanent magnets and soft metal pole pieces to connect the cone/filter assembly to the sampling head and vacuum supply. The cone/filter assembly is packaged in a plastic container and presterilized so that the need for any human contact during the sampling procedure is completely eliminated. Microbiological tests have demonstrated that the sampling efficiency is not affected by the magnetic coupling apparatus and that the probe appears to function as efficiently as the conventional plastic and Sandia vacuum probes.

Phillips, G. B.↗
NASA NTRS1984

Magnetic suspension options for spacecraft inertia-wheel applications

Design criteria for spacecraft inertia-wheel suspensions are listed. The advantages of magnetic suspensions over other suspension types for spacecraft inertia-wheel applications are cited along with the functions performed by magnetic suspension. The common designs for magnetic suspensions are enumerated. Materials selection of permanent magnets and core materials is considered.

Downer, J. R.↗
NASA NTRS1990

Improved Voice-Coil Actuators Have Lower Copper Losses

Improved design concept for electromagnetic linear-motion actuators of loudspeaker-voice-coil type reduces both copper losses (dissipation of power in electrical resistances of windings) and magnetic interference with other equipment. Includes closed magnetic circuit, which suppresses fringing flux. Pr/Fe/B permanent magnets yield better performance at lower temperatures. Intended for use where power supplies limited, heating must be minimized, and/or adequate performance at temperatures far below ambient required.

Simizu, Satoru↗
NASA NTRS1996

Development Of A Magnetic Directional-Solidification Furnace

Report describes development of directional-solidification furnace in which axial magnetic field is imposed by surrounding ring permanent magnets and/or electromagnets and pole pieces. Furnace provides controlled axial temperature gradients in multiple zones, through which ampoule containing sample of material to be solidified is translated at controlled speed by low-vibration, lead-screw, stepping-motor-driven mechanism. Intended for use in low-gravity (spaceflight) experiments on melt growth of high-purity semiconductor crystals.

Aldrich, Bill R.↗
NASA NTRS1999

Titanomagnetite-bearing Palagonitic Dust as an Analogue for Magnetic Aeolian Dust on Mars

The Mars Pathfinder magnetic properties experiment included two Magnet Arrays (MAs) which consist of five permanent magnets that have different strengths. Each magnet is a cylindrical and ring magnet arranged in a "bulls-eye" pattern beneath a thin surface layer. The design of the MA permits estimation of magnetic properties (saturation magnetization and magnetic susceptibility) of adhering material, principally by the number of magnets that have adhering material and the extent each magnet is saturated. The two MAs passively sample aeolian dust. Additional information is contained in the original extended abstract.

Morris, Richard V.↗
NASA NTRS2005

Integrated Power and Attitude Control System Demonstrated With Flywheels G2 and D1

On September 14, 2004, NASA Glenn Research Center's Flywheel Development Team experimentally demonstrated a full-power, high-speed, two-flywheel system, simultaneously regulating a power bus and providing a commanded output torque. Operation- and power-mode transitions were demonstrated up to 2000 W in charge and 1100 W in discharge, while the output torque was simultaneously regulated between plus or minus 0.8 N-m. The G2 and D1 flywheels--magnetically levitated carbon-fiber wheels with permanent magnet motors--were used for the experiment. The units were mounted on an air bearing table in Glenn's High Energy Flywheel Facility. The operational speed range for these tests was between 20,000 and 60,000 rpm. The bus voltage was regulated at 125 V during charge and discharge, and charge-discharge and discharge-charge transitions were demonstrated by changing the amount of power that the power supply provided between 300 and 0 W. In a satellite system, this would be the equivalent of changing the amount of energy that the solar array provides to the spacecraft. In addition to regulating the bus voltage, we simultaneously controlled the net torque produced by the two flywheel modules. Both modules were mounted on an air table that was restrained by a load cell. The load cell measured the force on the table, and the torque produced by the two flywheels on the table could be calculated from that measurement. This method was used to measure the torque produced by the modules, yielding net torques from -0.8 to 0.8 N-m. This was the first Glenn demonstration of the Integrated Power and Attitude Control System (IPACS) at high power levels and speeds.

Jansen, Ralph H.↗
DOE OSTI2020

Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors

Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling

42 ENGINEERING↗
DOE OSTI2025

Sorting rare earth magnets motors for recycling without opening the motors

Abstract A novel approach for sorting electric motors without dismantling them is reported in this article. This approach increases the likelihood that a motor selected from a mixture for recycling would contain rare earth elements (REEs), which are pivotal for numerous advanced green technologies. The challenge of inadvertently dismantling motors without REEs during recycling is addressed by this proposed innovative method. It relies on cogging interactions and power density for sorting motors with REEs. The process uses an algorithm introduced in this work to sort motors in two steps by (a) distinguishing induction motors from permanent magnet motors, and (b) distinguishing motors with critical REEs (e.g., Nd, Pr, Dy, Tb) from ferrite-based motors, all without opening the motors. The former was accomplished with 100% accuracy while the latter was accomplished with ~ 78% accuracy. Such high accuracy improves the recycling efficiency of critical REEs from motors, alleviating concern about supply disruption and supporting resource conservation and sustainability.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Medium Voltage Integrated Drive and Motor

The objective of this program was to design, build, and test a medium voltage (4,160VAC) high speed permanent magnet machine (HSPMM) and variable speed drive (VSD) that incorporates next generation 10kV silicon carbide (SiC) modules. The use of a HSPMM allows for high efficiency, small footprint, maintenance free operation while the SiC modules enable higher voltage operating conditions, improved efficiency, and small footprint.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

A comparison of efficiency-aware model-predictive control approaches for wave energy devices

In this study, we compare four different formulations of model predictive control that attempt to maximise electrical power generated by a wave energy converter (WEC). Control laws include (1) pure maximisation of mechanical power, (2) maximisation of mechanical power with a control penalty factor, (3) maximisation of electrical power using power conversion efficiency, and (4) maximisation of electrical power using the full electro-mechanical model of a system. For this study, a wave-to-wire model is developed for a floating spherical buoy connected to a permanent magnet synchronous generator. The performance of the controllers, including the mechanical and electrical power outputs, is compared in irregular wave conditions for the unconstrained and force-constrained scenarios. The results demonstrate that the controller designed to maximise mechanical power is not suitable for practical applications and may lead to negative electrical power output due to the non-ideal power take-off efficiency. Moreover, the replacement of the power take-off dynamics by the efficiency coefficient does not guarantee the maximum electrical power production.

16 TIDAL AND WAVE POWER↗
DOE OSTI2022

Advanced Lightweight HiE PMDD Generator for WTGs

Preliminary designs of advanced lightweight permanent magnet direct drive generators for offshore and “tall wind” onshore applications utilizing funding from DOE/EERE/WETO were developed by WEG, RTX, NREL and supporting partners. This work significantly reduces tower head mass, increases efficiency, reduces the rare earth content of the generator, and leads to additional turbine system benefits that improve competitiveness, such as the use of taller towers onshore and less expensive foundations (“hull”) for floating offshore. The end result is an approximately 10% reduction of LCOE in both cases, which could significantly improve competitiveness and support the EERE/DOE goal of promoting US manufacturing.

17 WIND ENERGY↗
DOE OSTI2025

The Ce-Fe-Ti System: Phase Equilibria in the Fe-rich Corner at 1000 °C

The rare earth–iron–transition metal systems are of increasing interest in the search for novel permanent magnet phases. This work reports on the solidification behavior, phase equilibria and stability range of solid phases in the ternary Ce-Fe-Ti system, focusing on the iron-rich region (> 65 at.% Fe) of the isothermal section at 1000 °C. Further, two ternary phases Ce 1.03 Fe 12-x Ti x (x = 0.87–1.02) with ThMn 12 structure type and Ce 3.06 Fe 27.6 Ti 1.4 with Nd 3 Fe 29 structure type were observed. Magnetic measurements of Ce 1.03 Fe 12-x Ti x and Ce 3.06 Fe 27.6 Ti 1.4 revealed ferromagnetic ordering with Curie temperatures of 550 K and 327 K, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure Alignment Effects from Engineered Cooling during Additive Manufacturing of Alnico Magnets from Prealloyed Powder

Alnico is a rare-earth free; permanent magnet (PM) which maintains its saturation magnetization while at temperatures up to 550°C but lacks the coercivity and energy product needed for a wide range of demanding applications. With an optimal set of processing and manufacturing techniques, Alnico could replace Dy-free Nd-Fe-B magnets in certain applications if the microstructure is textured in a $\langle$001$\rangle$ direction. Additive manufacturing (AM) of near-net-shape magnets may provide such texture. To investigate the possibility, directed-energy deposition (DED) in conjunction with an actively cooled substrate was used to build samples with a compositionally modified, gas-atomized, Alnico 8 alloy. The resulting samples were solutionized and quenched, followed by magnetic annealing and a heat treatment. Magnetic properties and microstructures are compared to previous work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mild hybridisation of turboprop engine with high-power-density integrated electric drives

Here this paper shares with the aerospace community a case study of turboprop mild hybridisation using a recently developed integrated drive system in the University of Nottingham, UK, within the ACHIEVE project under EU H2020 CleanSky 2 program (project No. 737814). The developed drive system enables green taxiing of a turboprop aircraft while on the ground with its engine off, and as an electrical generator when the turboprop is in the air. The entire system is designed to be able to integrate within the power auxiliary gear box (PAGB) of a turboprop aircraft. Some of the key features of the developed system include a high-speed permanent magnet machine (up to 14,200rpm) with dual three-phase design, SiC-based high power density (11.8kW/L for the power converter, 35.3kW/L and 7.2kW/kg for the machine active parts), integrated cooling design for high-temperature operation (>130°C ambient temperature), fault tolerance consideration with dual channel operation capabilities and sensorless control for entire operational conditions. This paper is giving an overview of the design process of the electrical machine, power converters, and its cooling of the entire drive. Numerical analysis (FEM and CFD) and some experimental results are presented to demonstrate the effectiveness and the desired performance of the developed integrated drive system.

42 ENGINEERING↗