Beam tests of a permanent magnet medical accelerator arc from 10-250 MeV
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43 PARTICLE ACCELERATORS↗
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Prediction and Control of Atomic Ordering in Electrodeposited Binary Alloy Films: Direct Synthesis of L10 Magnetic Phases
Permanent magnet materials are essential components in renewable energy technology, underlying, electric vehicles, hybrids, wind turbines and more. Today commercial permanent magnets based on Nd-Fe-B exhibit an energy product of ~ 400 kJ/m 3 , capable to run wind turbines efficiently. Unfortunately, the supplies of rare-earth elements are centralized, and their availability may see volatility over time. This state of affairs stimulates the search for the search for rare-earth-free permanent magnetic materials. The L1 0 crystal structure underlines an important class of chemical ordered alloys that exhibit uniaxial magnetocrystalline anisotropy. This material has been considered an excellent candidate for rare-earth-free permanent magnets. In this program, a series of systematic experiments were performed and analysed in order to understand the effect of each. In order to synthesize L 10-Fe-Ni, one has to circumvent the sluggish kinetic and the limited driving force resulted from the low order-disorder temperature (~320°C) of the system. A strategy was found to trigger a martensitic transformation from the FCC phase to one of the non-cubic phases by high-strain methods. The body-centered tetragonal Fe-Ni obtained by this strategy was considered as a precursor of L10 Fe-Ni. The formation of BCT Fe-Ni via a displacive process was also implemented at the nanoscale by using tailored AuNi@FeNi core@shell.
36 MATERIALS SCIENCE↗
Preservation of strain in iron nitride magnet
A permanent magnet may include a Fe 16 N 2 phase in a strained state. In some examples, strain may be preserved within the permanent magnet by a technique that includes etching an iron nitride-containing workpiece including Fe 16 N 2 to introduce texture, straining the workpiece, and annealing the workpiece. In some examples, strain may be preserved within the permanent magnet by a technique that includes applying at a first temperature a layer of material to an iron nitride-containing workpiece including Fe 16 N 2 , and bringing the layer of material and the iron nitride-containing workpiece to a second temperature, where the material has a different coefficient of thermal expansion than the iron nitride-containing workpiece. A permanent magnet including an Fe 16 N 2 phase with preserved strain also is disclosed.
Wang, Jian-Ping↗
Preservation of strain in iron nitride magnet
A permanent magnet may include a Fe 16 N 2 phase in a strained state. In some examples, strain may be preserved within the permanent magnet by a technique that includes etching an iron nitride-containing workpiece including Fe 16 N 2 to introduce texture, straining the workpiece, and annealing the workpiece. In some examples, strain may be preserved within the permanent magnet by a technique that includes applying at a first temperature a layer of material to an iron nitride-containing workpiece including Fe 16 N 2 , and bringing the layer of material and the iron nitride-containing workpiece to a second temperature, where the material has a different coefficient of thermal expansion than the iron nitride-containing workpiece. A permanent magnet including an Fe 16 N 2 phase with preserved strain also is disclosed.
Wang, Jian-Ping↗
Challenges in Postprocessing of Hybrid Manufacturing of Magnet Polymer Composites to Enhance the Energy Product of NdFeB Bonded Magnets
Bonded permanent magnets need to process magnetic filler particles and binder together which is a form of hybrid or composite manufacturing that needs to simultaneously process multimaterials. Polymer bonding of the permanent magnets decreases the energy product of the bonded magnets which varies with square of loading fraction of magnetic materials. However, due to high viscosity of bonding polymer prohibits loading higher than 80 volume % of magnetic materials in most efficient loading process such as compression molding. To further increase the loading of magnetic fraction in the bonded permanent magnets, it is expected to be beneficial to introduce a fraction of nonreacting thermally sacrificial polymer along with permanent bonding polymer in the least permissible of about 20 volume % of the polymer. This process of first adding the sacrificial polymer for higher processability for composites and later removing it via post processing such as heat treatment provides a simple example of inclusion of both the additive and the subtractive stages of hybrid manufacturing. These hybrid composite magnets can be heat treated to remove the sacrificial polymer to further increase the density and energy product which might require to implement hot isostatic pressing for compaction. Although the identification of such ideal polymer requires an extensive polymer chemistry research, we have compression molded several permanent bonding polymers such as nylon, polycarbonate (PC) and polyphenyl sulfide (PPS) and potential sacrificial polymer such as polyoxymethylene (POM), polystyrene (PS), and Acrylonitrile Butadiene Styrene (ABS) and heat treated to remove the sacrificial polymers. It is discovered that oxygen free low temperature pyrolizable polymers could be the potential candidates for increasing the magnet particles loading for achieving high energy products.
36 MATERIALS SCIENCE↗
A millimeter-wave tunneLadder TWT
A millimeter wave traveling wave tube was developed using a dispersive, high impedance forward interaction structure based on a ladder, with non-space harmonic interaction, for a tube with high gain per unit length and high efficiency. The TunneLadder interaction structure combines ladder properties modified to accommodate Pierce gun beam optics in a radially magnetized permanent magnet focusing structure. The development involved the fabrication of chemically milled, shaped ladders diffusion brazed to diamond cubes which are in turn active-diffusion brazed to each ridge of a doubly ridged waveguide. Cold test data are presented, representing the omega-beta and impedance characteristics of the modified ladder circuit. These results were used in small and large signal computer programs to predict TWT gain and efficiency. Actual data from tested tubes verify the predicted performance while providing broader bandwidth than expected.
Jacquez, A.↗
A magnetic suspension system with a large angular range
The paper describes a small-scale laboratory system, called the Large-Angle Magnetic Suspension Test Fixture (LAMSTF), constructed at NASA Langley Research Center in order to explore and develop technology required for the magnetic suspension of objects over large ranges of orientation. The LAMSTF hardware comprises five electromagnets in a circular arrangement, each driven from a separate bipolar power amplifier. The suspended element is a cylindrical axially magnetized permanent magnet core, within an aluminum tube. The element, which is 'levitated' by repulsive forces, is stabilized in five degrees-of-freedom, with rotation about the cylinder axis not controlled. The controller accommodates the changes in magnetic coupling between the electromagnets and the suspended element by real-time adaptation of a decoupling matrix. The paper presents performance measurements demonstrating that the major design objective of the 360 deg rotation was accomplished.
Britcher, Colin P.↗
Three-axis force actuator for a magnetic bearing
This invention features a three-axis force actuator that axially, radially and rotatably supports a bearing member for frictionless rotation about an axis of rotation generally coincident with a Z-axis. Also featured is a magnetic bearing having such an actuator. The actuator includes an inner member, a magnetic member and a pole assembly having a ring member and four pole extending therefrom. The poles are equi-angular spaced from each other and radially spaced about the Z-axis. The inner member extends along the Z-axis and is a highly magnetic permeable material. The magnetic member is formed about the inner member outer surface, extends along the Z-axis and is configured so one magnetic pole polarity is located at its outer surface and the other polarity pole is located at its inner surface. Preferably, the magnetic member is a radially magnetized permanent magnet. The inner surface of the ring member is magnetically coupled to the magnetic member and a face of each pole is coupled to the bearing member. The magnetic member, the pole assembly, the inner member and the bearing member cooperate to generate a magnetic field that radially and rotatably supports a rotating member secured to the bearing member. The actuator further includes a plurality of electromagnetic coils. Preferably, a coil is formed about each pole and at least 2 coils are formed about the inner member. When energized, the electromagnetic coils generate a modulated magnetic field that stabilizes the rotating member in the desired operational position.
Gondhalekar, Vijay↗
Design Issues for Using Magnetic Materials in Radiation Environments at Elevated Temperature
One of the challenges of designing motors and alternators for use in nuclear powered space missions is accounting for the effects of radiation. Terrestrial reactor power plants use distance and shielding to minimize radiation damage but space missions must economize volume and mass. Past studies have shown that sufficiently high radiation levels can affect the magnetic response of hard and soft magnetic materials. Theoretical models explaining the radiation-induced degradation have been proposed but not verified. This paper reviews the literature and explains the cumulative effects of temperature, magnetic-load, and radiation-level on the magnetic properties of component materials. Magnetic property degradation is very specific to alloy choice and processing history, since magnetic properties are very much entwined with specific chemistry and microstructural features. However, there is basic theoretical as well as supportive experimental evidence that the negative impact to magnetic properties will be minimal if the bulk temperature of the material is less than fifty percent of the Curie temperature, the radiation flux is low, and the demagnetization field is small. Keywords: Magnets, Permanent Magnets, Power Converters, Nuclear Electric Power Generation, Radiation Tolerance.
Bowman, Cheryl L.↗
Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets
Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.
design optimization↗
Electron back scattered diffraction characterization of Sm(CoFeCuZr){sub z} magnets
In permanent magnets based on the Sm{sub 2}Co{sub 17} phase, the high coercivity depends on the presence of a complex microstructure, consisting of a Sm{sub 2}(Co,Fe){sub 17} cell phase, a cell boundary phase Sm(Co,Cu){sub 5}, and a Zr-rich platelet or lamellae phase. The aim of this work is to use electron back scatter diffraction (EBSD) in order to identify the different phases present in the isotropic magnets produced from cast alloys with the composition of Sm(Co{sub bal}Fe{sub 0.2}Cu{sub 0.1}Zr{sub x}){sub 8}, where x = 0, 0.02, or 0.06, and correlate them with the different phases observed in scanning electron microscopy (SEM) images. Due to the combination of careful surface preparation and high resolution microscopy, it was possible to observe the cellular structure characteristic of the 2:17 magnets in the SEM images. Until now, only transmission electron microscopy (TEM) had been used. Composition maps, energy dispersive spectroscopy (EDS), and EBSD measurements were used for doing the phase identification.
36 MATERIALS SCIENCE↗
Investigation of Powder Processing, Heat Treating, and Texturing to Improve Gas Atomized alnico Magnets for use in Electric Drive Motors
Alnico permanent magnet materials have been proposed as a rare earth free permanent magnet alternative during an ongoing search to replace rare earth permanent magnets that are used for interior permanent magnet motors, a common motor found in electric vehicles. A powder processing approach was used to study two alnico alloys (Full-Co and lower cost Co-Lean, both with enhanced coercivity) to anticipate high volume manufacturing needed to supply millions of permanent magnets to interior permanent magnet motors. In this study the two alloys were gas atomized, compression molded, and solid-state sintered to fabricate near-final shape alnico magnets. The Full-Co displayed abnormal grain growth (resulting in >1 mm size grains) during sintering while the Co-Lean did not (~20 μm – 400 μm sized grains depending on the sintering hold times). Solid state grain alignment was used to promote a <001> textured (easy axis) microstructure to enhance magnetic properties, yet both alloys did not show predicted grain alignment behavior. Comparisons of the powder processing, microstructures, and magnetic properties of the two alloys will be discussed, as well as an evaluation as to why non-theoretical processing behavior of the Full-Co and Co-Lean alnico permanent magnets is occurring. Preliminary interior permanent magnet motor designs for alnico magnets are discussed, as this is the overarching objective for powder-based alnico permanent magnets.
Rinko, Emily↗
Processing of Alnico Magnets by Additive Manufacturing
Permanent magnets without rare earth (RE) elements, such as alnico, will improve supply stability and potentially decrease permanent magnet cost, especially for traction drive motors and other increased temperature applications. Commercial alnico magnets with the highest energy product are produced by directional solidification (DS) to achieve a < 001 > columnar grain orientation followed by significant final machining, adding to the high cost. Additive manufacturing (AM) is an effective method to process near net-shape parts with minimal final machining of complex geometries. AM also, has potential for texture/grain orientation control and compositionally graded structures. This report describes fabrication of alnico magnets by AM using both laser engineered net shaping (LENS)/directed energy deposition (DED) and electron beam melting powder bed fusion (EBM/PBF). High pressure gas atomized (HPGA) pre-alloyed alnico powders, with high purity and sphericity, were built into cylindrical and rectangular samples, followed by magnetic annealing (MA) and a full heat treatment (FHT). The magnetic properties of these AM processed specimens were different from their cast and sintered counterparts of the same composition and show a great sensitivity to heat treatment. The AM process parameters used in this developmental study did not yet result in any preferred texture within the alnico AM builds. These findings demonstrate feasibility for near net-shape processing of alnico permanent magnets for use in next generation traction drive motors and other applications requiring increased operating temperatures and/or complex engineered part geometries, especially with further AM process development for texture control.
36 MATERIALS SCIENCE↗
Design Features of a Planar Hybrid/Permanent Magnet Strong Focusing Undulator for Free Electron Laser (FEL) And Synchrotron Radiation (SR) Applications
Insertion devices for Angstrom-wavelength Free Electron Laser (FEL) amplifiers driven by multi-GeV electron beams generally require distributed focusing substantially stronger than their own natural focusing fields. Over the last several years a wide variety of focusing schemes and configurations have been proposed for undulators of this class, ranging from conventional current-driven quadrupoles external to the undulator magnets to permanent magnet (PM) lattices inserted into the insertion device gap. In this paper we present design studies of a flexible high-field hybrid/PM undulator with strong superimposed planar PM focusing proposed for a 1.5 Angstrom Linac Coherent Light Source (LCLS) driven by an electron beam with a 1 mm-mr normalized emittance. Attainable field parameters, tuning modes, and potential applications of the proposed structure are discussed.
43 PARTICLE ACCELERATORS↗
Model for Generation of Neutrons in a Compact Diode with Laser-Plasma Anode and Suppression of Electron Conduction Using a Permanent Cylindrical Magnet
A model for acceleration of deuterons and generation of neutrons in a compact laser-plasma diode with electron isolation using magnetic field generated by a hollow cylindrical permanent magnet is presented. Experimental and computer-simulated neutron yields are compared for the diode structure under study. An accelerating neutron tube with a relatively high neutron generation efficiency can be constructed using suppression of electron conduction with the aid of a magnet placed in the vacuum volume.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Effects of Ag additions on melt-spun RE2Fe14B microstructure and texture
Control of microstructure and texture is of critical importance in forming rare earth (RE)-iron-boron particulate suitable for anisotropic polymer-bonded permanent magnets and anisotropic sintered permanent magnets. In this study, the selected approach to controlling grain size, while maintaining texture, is through stabilization and refinement of directional growth in melt-spun ribbons. Varying concentrations of Ag were added to melt-spun ribbons of composition (Y0.55Nd0.45)2.2Fe14B1.1. Effects on microstructure and texture were observed through scanning electron microscopy (SEM) and x-ray diffraction (XRD). It was determined that Ag stabilized columnar growth (compared to alloys with no Ag added) with additions as small as 0.3 at. %, but the Ag also produced a unique texture in the ribbons. In RE-Fe-B ribbons without Ag, strong <00l> texture is observed at the free surface and a mechanism has been established. In all Ag-containing ribbons, the observed texture is canted to both the c- and a-axes, but the mechanism remains unclear.
36 MATERIALS SCIENCE↗
Improvements to the Powder Processing of near-Final Shape alnico Magnets
Alnico permanent magnets (PMs), a recent PM system of interest as an attractive rare earth-free PM alternative, have advantageous high operating temperature and magnetic saturation with the potential for utilization in electric machines, e.g. interior-PM motors found in electric vehicles, if current directional solidification methods can be replaced by a true mass production approach. Recently, two unique alnico compositions, termed Full-Co and Co-lean, with improved coercivity, were gas atomized, compression molded, and vacuum sintered (4h at 1240°C) to high densities of 97.8% and 99.3%, respectively. However, the Co-lean remained fine grained isotropic magnets and the Full-Co grains were not textured, lowering magnetic strength in spite of attempts to grow large textured grains by a stress-biased solid state grain alignment method to convert them to high energy anisotropic magnets. It was hypothesized that oxidation during de-binding in air left many prior particle boundary oxides within the sintered microstructure that hindered grain growth and texturing during the stress-biased texturing procedure and prevented the desired abnormal grain growth (AGG). Here we explored a vacuum de-binding step that was linked (in-place) to vacuum sintering and found that the Co-lean exhibited faster uniform grain growth that doubled the average grain size (40 μm to 80 μm). Linked vacuum de-binding and sintering of Full-Co produced some AGG after only 1 h of 1240°C sintering. A new direction for promoting AGG (and stress-biased texturing) in alnico is being explored that utilizes a fundamental analysis of systems with second phase particles that either inhibit or boost grain growth. This effort explores the influence of vacuum de-binding linked to a series of lower sintering temperatures at a fixed time (4h) to see if oxide particle size and volume fraction can be changed to promote AGG conditions in alnico. Surprising qualitative results indicate that AGG may be promoted for vacuum sintering at less than 1200°C.
Rinko, Emily↗
Study of free-piston Stirling engine driven linear alternators
The analysis, design and operation of single phase, single slot tubular permanent magnet linear alternator is presented. Included is the no-load and on-load magnetic field investigation, permanent magnet's leakage field analysis, parameter identification, design guidelines and an optimal design of a permanent magnet linear alternator. For analysis of the magnetic field, a simplified magnetic circuit is utilized. The analysis accounts for saturation, leakage and armature reaction.
Nasar, S. A.↗