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DOE OSTI2025

Cold Spray Cobalt Magnetostrictive Electromagnetic Acoustic Transducers for High Temperature Structure Monitoring

The Department of Energy’s Advanced Sensors and Instrumentation program seeks to develop and qualify advanced sensors for the nuclear industry. Reliable high temperature and high radiation sensors for detection and characterization of structural flaws in pipes, vessels, and structurally critical components is a weakness for both conventional light water reactors with coolant T-hot approaching 350oC, and for advanced reactors with T-hot temperatures in excess of 500 to 800oC. Magnetostrictive Electromagnetic Acoustic Transducers using a cold spray cobalt coating have been proposed as a sensor design that can withstand these kinds of temperatures and radiation levels to serve as online sensors to detect flaws before cracks, pits, or erosion/corrosion flaws progress to through-wall failures. This report tests cold spray cobalt as part of a magnetostrictive EMAT for high temperature service. Cobalt is known to have strong magnetostrictive properties however the effect of cold spray application is not well studied. This program was surprised to discover that cold sprayed cobalt exhibited little or no magnetostrictive behavior until it was thermally annealed. Following annealing to 650oC however, cold spray cobalt did exhibit a magnetostrictive response. Work to date prior to this milestone report publication showed that magnetostrictive EMAT was successfully tested to 400oC with an alnico permanent magnet. The program plans to extend testing with an electromagnet to higher temperatures. This follow-on work will be reported under subsequent publications or as a revision to this report.

Glass, Samuel W.↗

NASA NTRS2016

Wear Testing of the HERMeS Thruster

The Hall-Effect Rocket with Magnetic Shielding (HERMeS) thruster is being developed and tested at NASA GRC and NASA JPL through support of the Space Technology Mission Directorate (STMD) as primary propulsion for the Asteroid Redirect Robotic Mission (ARRM). This thruster is advancing the state-of-the-art of Hall-effect thrusters and is intended to serve as a precursor to higher power systems for human interplanetary exploration. A 2000-hour wear test has been initiated at NASA GRC with the HERMeS Technology Demonstration Unit One and three of four test segments have been completed totaling 728 h of operation. This is the first test of a NASA-designed magnetically shielded thruster to extend beyond 300 hr of continuous operation. Trends in performance, component wear, thermal design, plume properties, and back-sputtered deposition are discussed for two wear-test segments of 246 h and 360 h. The first incorporated graphite pole covers in an electrical configuration where cathode was electrically connected to thruster body. The second utilized traditional alumina pole covers with the thruster body floating. It was shown that the magnetic shielding in both configurations completely eliminated erosion of the boron nitride discharge channel but resulted in erosion of the inner pole cover. The volumetric erosion rate of the graphite pole covers was roughly 2/3 that of the alumina pole covers and the thruster exhibited slightly better performance. Buildup of back-sputtered carbon on the BN channel at a rate of roughly 1.5 μm/kh is shown to have negligible impact on the performance.

Thruster↗

DOE OSTI2020

Test Results of Fast Decaying Current-Induced AC Losses in SHMS Superconducting Magnets at Jefferson Lab

The 11 GeV Super High Momentum Spectrometer (SHMS) of Hall C, part of the recent 12 GeV accelerator Upgrade at Jefferson Lab, was successfully commissioned in 2017. Fast current discharges of the SHMS Q2, Q3 quadrupoles and dipole superconducting magnets experienced some level of operational difficulty, during commissioning and normal operation. Measurements and analyses demonstrate that the fast current discharge leads to substantial AC losses in the conductor and subsequently triggers a quench-back effect. The details of the measurements and analyses have been reported previously. This paper focuses on the test results of the magnets using a reduced value of the protection dump resistor for each magnet to lower the current decay rate. Finally, the test results confirmed that the reduced dump resistances eliminated the quench-back effect for the SHMS Q2, Q3 and Dipole magnets, thus improving their cryogenic operability.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1995

Non-destructive Testing (NDT) of metal cracks using a high Tc rf-SQUID and eddy current method

A SQUID is the most sensitive device to detect change in magnetic field. A nondestructive testing (NDT) device using high temperature SQUID's and eddy current method will be much more sensitive than those currently used eddy current systems, yet much cheaper than one with low temperature SQUID's. In this paper, we present our study of such a NDT device using a high temperature superconducting rf-SQUID as a gradiometer sensor. The result clearly demonstrates the expected sensitivity of the system, and indicates the feasibility of building a portable HTS SQUID NDT device with the help from cryocooler industry. Such a NDT device will have a significant impact on metal corrosion or crack detection technology.

Lu, D. F.↗

NASA NTRS1992

Active magnetic bearings: As applied to centrifugal pumps

Application of magnetic bearings to boiler feed pumps presents various attractive features, such as longer bearing life, lower maintenance costs, and improved operability through control of the rotordynamics. Magnetic bearings were fitted to an eight-stage, 600 hp boiler feed pump, which generates 2600 ft of heat at 680 gpm and 3560 rpm. In addition to the varied and severe operating environment in steady state operation of this pump in a power plant, it is also subjected to transient loads during frequent starts and stops. These loads can now be measured by the in-built instrumentation of the magnetic bearings. Following site installation, a follow-up bearing tune-up was performed, and pump transient response testing was conducted. The bearing response was completely satisfactory, ensuring trouble-free pump operation even in the range of reduced load. The experience gained so far through design and testing proves feasibility of magnetic bearings for boiler feed pumps, which sets the stage for application of even higher energy centrifugal pumps equipped with magnetic bearings.

Lev Nelik↗

NASA NTRS1975

Development of superconductor magnetic suspension and balance prototype facility for studying the feasibility of applying this technique to large scale aerodynamic testing

The unique design and operational characteristics of a prototype magnetic suspension and balance facility which utilizes superconductor technology are described and discussed from the point of view of scalability to large sizes. The successful experimental demonstration of the feasibility of this new magnetic suspension concept of the University of Virginia, together with the success of the cryogenic wind-tunnel concept developed at Langley Research Center, appear to have finally opened the way to clean-tunnel, high-Re aerodynamic testing. Results of calculations corresponding to a two-step design extrapolation from the observed performance of the prototype magnetic suspension system to a system compatible with the projected cryogenic transonic research tunnel are presented to give an order-of-magnitude estimate of expected performance characteristics. Research areas where progress should lead to improved design and performance of large facilities are discussed.

Zapata, R. N.↗

DOE OSTI2022

Improvements on the Diagnostic Residual Gas Analyzer at Wendelstein 7-X

Exhaust gas analysis provides key information on fusion processes, divertor operation, and wall state in fusion experiments and future reactors. The diagnostic residual gas analyzer (DRGA) concept has been developed for ITER with a focus on fast helium and hydrogen isotope detection. The first operation of the prototype DRGA (P-DRGA) at the stellarator Wendelstein 7-X showed potential for improvement in terms of magnetic sensor shielding, data acquisition automation, and potential new additions to the cluster of sensors on the P-DRGA. More recently, a Monte Carlo simulation of the flow of the mixed gas species effluent from the pressure-reducing orifice, down to about 8-m sampling tube and into the analysis region of the sensors, has been found to generally agree with previous calculations and measurements but revealed potential back-streaming effects for light gases, with impact on detection limits both for the prototype and for the ITER DRGA currently in design. For the upcoming campaign of the prototype, an enhanced soft iron shield will safeguard the gauges against magnetic stray field influence. The newly introduced shielding has been tested for its effect on magnetic stray fields and found to reduce the inside residual field by about two orders of magnitude.

Schlisio, G↗

NASA NTRS2004

Using Magnetic Fields to Control Convection during Protein Crystallization: Analysis and Validation Studies

The effect of convection during the crystallization of proteins is not very well understood. In a gravitational field, convection is caused by crystal sedimentation and by solutal buoyancy induced flow and these can lead to crystal imperfections. While crystallization in microgravity can approach diffusion limited growth conditions (no convection), terrestrially strong magnetic fields can be used to control fluid flow and sedimentation effects. In this work, we develop the analysis for magnetic flow control and test the predictions using analog experiments. Specifically, experiments on solutal convection in a paramagnetic fluid were conducted in a strong magnetic field gradient using a dilute solution of Manganese Chloride. The observed flows indicate that the magnetic field can completely counter the settling effects of gravity locally and are consistent with the theoretical predictions presented. This phenomenon suggests that magnetic fields may be useful in mimicking the microgravity environment of space for some crystal growth ana biological applications where fluid convection is undesirable.

Ramachandran, N.↗

DOE OSTI2022

HTS Cable Conductor for Compact Fusion Tokamak Solenoids

Significant progress has been made recently in the US fusion community to develop a strategic plan to enable engineering design and construction of a fusion pilot plant (FPP). Princeton Plasma Physics Laboratory (PPPL) is working on developing high current density HTS conductors for next fusion experiments. Partnering with the US industry, we are evaluating feasibility and affordability of Conductor on Round Core (CORC ® ) developed by Advanced Conductor Technologies (ACT) for the next compact fusion tokamak facility. High current density achieved by a CORC ® cable based on a four-layer model coil recently tested at National High Magnetic Field Laboratory (NHMFL) motivated its consideration for low cost, reduced size fusion magnet application. This is of interest to PPPL because of its scalability to tokamak central solenoid (CS) coils in terms of required flux swings for plasma startup operations. Furthermore, partnering with ACT, we designed and built a two-layer model coil solenoid directly wound with CORC to demonstrate its applicability for compact solenoids such as that used in the national spherical torus experiment (NSTX), NSTX-upgrade (NSTX-U) and the US sustained high-power density test facility (SHPD). The ~160 mm diameter solenoid wound by a two-layer CORC is being tested in early 2022 under electromagnetic cyclic loading at NHMFL in a unique 160 mm bore, 14 T background field magnet facility.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Performance of a MQXF Nb 3 Sn Quadrupole Magnet Under Different Stress Level

In a dipole or in a quadrupole accelerator magnet, the displacement of the coil turns induced by the electromagnetic forces can cause quenches limiting the magnet performance. For this reason, an azimuthal preload is applied to avoid azimuthal movements of the coil up to the required operational current. However, several tests showed that accelerator magnets can operate with a partial preload, i.e. that coil unloading during the ramp does not prevent reaching higher currents. This issue is particularly relevant for Nb 3 Sn magnets, where the loads applied to the Nb3Sn filaments can reach the degradation limits of critical current. In order to investigate the impact of coil preload on the quench performance, the MQXFS6 short model quadrupole for the High Luminosity Upgrade was tested under an azimuthal preload at 80% of the short sample current, reaching 93% of short sample current at 1.9 K. The preload was then released to 60%, still showing ability to operate in the range of 80-85% of short sample current as required by HL-LHC project. With this lower preload, the ability of going above 90% of short sample was lost, and a significant training appeared above 85%. When the preload was restored to the original 80% value, the magnet reached with few quenches 95% of short sample (13.4 T peak field). Magnetic measurements confirm the larger movement of the coil in the case with lower preload, and agree with finite element simulations.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1993

SPDE/SPRE final summary report

Mechanical Technology Incorporated (MTI) performed acceptance testing on the Space Power Research Engine (SPRE), which demonstrated satisfactory operation and sufficient reliability for delivery to NASA Lewis Research Center. The unit produced 13.5 kW PV power with an efficiency of 22 percent versus design goals of 28.8 kW PV power and efficiency of 28 percent. Maximum electric power was only 8 kWe due to lower alternator efficiency. One of the major shortcomings of the SPRE was linear alternator efficiency, which was only 70 percent compared to a design value of 90 percent. It was determined from static tests that the major cause for the efficiency shortfall was the location of the magnetic structure surrounding the linear alternator. Testing of an alternator configuration without a surrounding magnetic structure on a linear dynamometer confirmed earlier static test results. Linear alternator efficiency improved from 70 percent to over 90 percent. Testing of the MTI SPRE was also performed with hydrodynamic bearings and achieved full-stroke, stable operation. This testing indicated that hydrodynamic bearings may be useful in free piston Stirling engines. An important factor in achieving stable operation at design stroke was isolating a portion of the bearing length from the engine pressure variations. In addition, the heat pipe heater head design indicates that integration of a Stirling engine with a heat source can be performed via heat pipes. This design provides a baseline against which alternative designs can be measured.

Dochat, George↗

NASA NTRS1991

Determination of the coronal magnetic field from vector magnetograph data

A new algorithm was developed, tested, and applied to determine coronal magnetic fields above solar active regions. The coronal field above NOAA active region AR5747 was successfully estimated on 20 Oct. 1989 from data taken at the Mees Solar Observatory of the Univ. of Hawaii. It was shown that observational data can be used to obtain realistic estimates of coronal magnetic fields. The model has significantly extended the realism with which the coronal magnetic field can be inferred from observations. The understanding of coronal phenomena will be greatly advanced by a reliable technique, such as the one presented, for deducing the detailed spatial structure of the coronal field. The payoff from major current and proposed NASA observational efforts is heavily dependent on the success with which the coronal field can be inferred from vector magnetograms. In particular, the present inability to reliably obtain the coronal field has been a major obstacle to the theoretical advancement of solar flare theory and prediction. The results have shown that the evolutional algorithm can be used to estimate coronal magnetic fields.

Mikic, Zoran↗

NASA NTRS2016

Wear Testing of the HERMeS Thruster

Thruster↗

NASA NTRS2005

Magnetic Control of Concentration Gradient in Microgravity

A report describes a technique for rapidly establishing a fluid-concentration gradient that can serve as an initial condition for an experiment on solutal instabilities associated with crystal growth in microgravity. The technique involves exploitation of the slight attractive or repulsive forces exerted on most fluids by a magnetic-field gradient. Although small, these forces can dominate in microgravity and therefore can be used to hold fluids in position in preparation for an experiment. The magnetic field is applied to a test cell, while a fluid mixture containing a concentration gradient is prepared by introducing an undiluted solution into a diluting solution in a mixing chamber. The test cell is then filled with the fluid mixture. Given the magnetic susceptibilities of the undiluted and diluting solutions, the magnetic-field gradient must be large enough that the magnetic force exceeds both (1) forces associated with the flow of the fluid mixture during filling of the test cell and (2) forces imposed by any residual gravitation and fluctuations thereof. Once the test cell has been filled with the fluid mixture, the magnetic field is switched off so that the experiment can proceed, starting from the proper initial conditions.

Leslie, Fred↗

NASA NTRS1976

Magnetic bearing reaction wheel

The results of a program for the development, fabrication and functional test of an engineering model magnetically suspended reaction wheel are described. The reaction wheel develops an angular momentum of + or - 0.5 foot-pound-second and is intended for eventual application in the attitude control of long-life interplanetary and orbiting spacecraft. A description of the wheel design and its major performance characteristics is presented. Recommendations for flight prototype development are made.

Sabnis, A.↗

NASA NTRS1988

The effect of sting interference at low speeds on the drag coefficient of an ellipsoidal body using a magnetic suspension and balance system

A Boltz body of revolution (fineness ratio 7.5:1) was tested in the Southampton University Magnetic Suspension and Balance System. The effects of sting interference on the drag coefficient of the model at zero angle of attack were noted as well as the effects on drag coefficient values at boundary layer trips. The drag coefficient values were compared with other sources and seemed to show agreement. The pressure distribution over the rear of the model with no sting interference was investigated including the use of boundary layer trips.

Newcomb, A. W.↗

DOE OSTI2026

Detecting shearless phase-space transport barriers in global gyrokinetic turbulence simulations with test particle map models

In magnetically confined fusion plasmas, the role played by zonal 𝐸 x 𝐵 flow shear layers in the suppression of turbulent transport is relatively well understood. However, less is understood about the role played by the weak shear regions that arise in the non-monotonic radial electric field profiles often associated with these shear layers. In electrostatic simulations from the global total-𝑓 gyrokinetic particle-in-cell code XGC, we demonstrate how shearless regions with non-zero flow curvature form zonal ‘jets’ that, in conjunction with neighbouring regions of shear, can act as robust barriers to particle transport and turbulence spreading. By isolating quasi-coherent fluctuations radially localised to the zonal jets, we construct a map model for the Lagrangian dynamics of gyrokinetic test particles in the presence of drift waves. We identify the presence of shearless invariant tori in this model and verify that these tori act as partial phase-space transport barriers in the simulations. We also demonstrate how avalanches impinging on these shearless tori cause eddy detachment events that form ‘cold/warm core ring’ structures analogous to those found in oceanic jets, facilitating transport across the barriers without destroying them completely. We discuss how shearless tori may generically arise from tertiary instabilities or other types of discrete eigenmodes, suggesting their potential relevance to broader classes of turbulent fluctuations.

fusion plasma↗

DOE OSTI2026

Design and Construction of a Superconducting “Direct Wind” R&D Magnet for the EIC Interaction Region

Brookhaven National Laboratory (BNL) was chosen to host the international Electron-Ion Collider (EIC), which will collide high energy and highly polarized hadron and electron beams with a center of mass energy up to 140 GeV. The Interaction Region (IR) [1] requires several large aperture, relatively high field superconducting dipole and quadrupole magnets, some of which are very closely spaced.\r\nA value engineering effort is underway as part of the EIC Project to construct and test a Direct Wind magnet [2] (coil comprised of NbTi conductor deposited directly onto a support tube, in this instance tapered, and secured mechanically against Lorentz forces afterwards) to replace two Rutherford cable collared magnets. This magnet exceeds the combination of aperture, number of coil \r\nlayers, and magnetic field, as compared to existing accelerator and R&D Direct Wind magnets to date. Furthermore, construction has been completed using a newly commissioned winding machine, upgraded in anticipation of the upcoming EIC production coil fabrication. Design, analysis, construction issues, lessons learned and accomplishments to date shall be discussed, including the \r\nachieved corrections to multipoles made to successive coil layers based on warm magnetic measurements of preceding layers.

43 PARTICLE ACCELERATORS↗