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All sources NASA NTRS DOE OSTI

DOE OSTI2026

Novel thermal energy storage component: Development, performance, and phase transition diagnosis

Thermal energy storage (TES) using phase change materials (PCMs) is a promising technology for capturing and storing excess thermal energy for later use. However, challenges such as poor heat transfer efficiency and a lack of modular, scalable designs have limited widespread adoption of TES in real-world applications. This study developed and evaluated modular brick-type and blade-type TES prototypes featuring an aluminum housing, an embedded serpentine coil for active or passive thermal exchange, and a cost-effective metal mesh to enhance PCM thermal conductivity. The blade-type TES achieved notable geometric efficiency, with a thickness-to-length ratio of 0.03 and a thickness-to-width ratio of 0.08, enabling highly compact and modular thermal storage suitable for space-constrained applications. The paper presents a detailed evaluation of the TES prototypes’ performance. The comparative analysis indicated that the TES prototypes provide a highly cost-effective, thermally optimized alternative for compact energy storage and load shifting. A novel diagnostic technique was also introduced: using a portable endoscope to capture real-time visualizations of PCM phase transitions inside the TES. This method provides critical insights into internal heat transfer mechanisms, identifies potential issues, and offers valuable support for optimizing the TES design and developing the control algorithm. Overall, the modular brick-type and blade-type TES designs demonstrated in this work provide a scalable, efficient, and economically viable solution for advancing TES across residential, commercial, and industrial sectors. The designs’ compact structure, enhanced thermal performance, and integrated diagnostic capabilities make them strong candidates for future deployment in energy-efficient systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

DOE OSTI2024

ORBUMP Pulsed Dipole Magnet Design for Fermilab Booster

Fermilab initiated the accelerator magnet system upgrade project PIP-II for future neutrino experiments. Old ORBUMP pulsed dipoles should be replaced with new stronger magnets occupying the same space as old ones. Four of these magnets connected in series form dogleg type of proton beam orbit. The magnet field and 19 kA current pulse length are close to 1 ms. Old magnet cores were based on a ferrite material. For new magnets, a magnet gap field is above 0.4 T, which completely saturates ferrite material. So, for the magnet core, 0.127 mm thick laminations of low carbon steel with inorganic coating, as the magnet were placed in a vacuum box. There were investigated transient magnet parameters including skin effect in the iron core and in the single-turn copper coil. The integrated field homogeneity was improved by the copper coil shimming. Simulated by OPERA3D power losses were used for the thermal analysis by ANSYS code. The magnet performance is strongly coupled with the power source. The dynamic magnet inductance and resistance were included in the pulsed power source design. Finally, the paper presented the ORBUMP magnet system design.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Electromagnetic Shielding Design for 200 kW Stationary Wireless Charging of Light-Duty EV

Wireless power transfer (WPT) is a developing technology with the advantage of convenience and flexible charging. SAE recommended practice J2954 defines typical size and geometry with aluminum or ferrite plate shielding to limit leakage electromagnetic (EM) fields for WPT with power levels lower than 22 kVA from the input side. However, as the WPT power goes up to 100- or 200-kW level, EM safety surrounding the WPT becomes a critical concern. To address this oncoming safety challenge, a novel ferrite shielding design is proposed in this paper. Different misalignment scenarios in accordance with definitions in SAE J2954 are also taken into consideration to ensure EM safety under various operation scenarios. Simulation results, which are preliminarily verified by magnetic field measurements at 1.1 m from the center of the vehicle side coil under 100 kW operation, indicate that the magnetic field leakage can be maintained below the limits defined in SAE J2954 for 200 kW operation. A 3.3 kW scale-down test was also carried out and compared to parallel scale-down simulations. 26.8% field emission reduction is observed from the scale-down test, which supports the effectiveness of the proposed shielding design.

Zhang, Bo↗

DOE OSTI2020

Electromagnetic Shielding Design for 200 kW Stationary Wireless Charging of Light-Duty EV

25 ENERGY STORAGE↗

DOE OSTI2022

Wire-coil insert optimization for high-heat-load/flux synchrotron components

Many synchrotron components require high levels of internal-flow, forced-convection heat transfer to minimize surface temperatures, thermal gradients, and thermally induced stress on high-power beam-interacting surfaces. Wire-coil inserts, physically similar to a common spring, are mechanically fitted inside of component cooling passages to optimize heat transfer performance. They are routinely used in Advanced Photon Source (APS) front end and beamline high-heat-load/flux components to significantly enhance convection heat transfer-up to 400% compared to plain open passages. This has the additional benefit of greatly reducing coolant flow requirements for these components. Using several cooling passage sizes, five different wire sizes, and a range of pitch values, an experimental investigation conducted at the APS has determined the average heat transfer coefficient and resulting pressure loss as a function of water flow rate for 65 different wire-coil inserts. Data from this study have been non-dimensionalized and generalized to yield relationships that can be used to determine the heat transfer performance and resulting pressure loss for any given wire-coil insert that may be used at the APS. Through data reduction, the wire-coil insert characteristic dimensions have also been optimized to yield the highest heat transfer enhancement while minimizing the coolant flow requirements. These generalized expressions for wirecoil inserts will be presented, and they can be used by scientists and engineers during the component design process to evaluate achievable heat transfer performance and associated pressure loss, aiding in the establishment of optimized operating parameters and cooling passage flow distribution schemes.

43 PARTICLE ACCELERATORS↗

NASA NTRS1997

The Microgravity Vibration Isolation Mount: A Dynamic Model for Optimal Controller Design

Vibration acceleration levels on large space platforms exceed the requirements of many space experiments. The Microgravity Vibration Isolation Mount (MIM) was built by the Canadian Space Agency to attenuate these disturbances to acceptable levels, and has been operational on the Russian Space Station Mir since May 1996. It has demonstrated good isolation performance and has supported several materials science experiments. The MIM uses Lorentz (voice-coil) magnetic actuators to levitate and isolate payloads at the individual experiment/sub-experiment (versus rack) level. Payload acceleration, relative position, and relative orientation (Euler-parameter) measurements are fed to a state-space controller. The controller, in turn, determines the actuator currents needed for effective experiment isolation. This paper presents the development of an algebraic, state-space model of the MIM, in a form suitable for optimal controller design.

Hampton, R. David↗

DOE OSTI2022

PM4Stell: A prototype permanent magnet stellarator structure

Permanent magnets provide a possible solution to simplify complicated stellarator coils. Here, a prototype permanent magnet stellarator structure, PM4Stell, has been funded to demonstrate the technical feasibility of using permanent magnets to create the shaping field of a stellarator. Permanent magnets in uniform cubes with three polarization directions will be carefully placed to generate the required magnetic field for a National Compact Stellarator eXperiment-like equilibrium together with planar toroidal field coils. Discrete magnets will be glued together and inserted into a “post-office-box-like” supporting structure. Electromagnetic and structural analyses have been done to validate the design. Error field correction magnets will be used to shim possible error fields. The design efforts of the prototype permanent magnet stellarator structure are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Thermal Analysis of a 50 kW Three-Phase Wireless Charging System

In this paper, the thermal analysis of a 50 kW three-phase wireless charging system (WCS) is presented. Addressing the thermal challenge is essential for designing a compact charging pad for 50 kW and higher-power WCS pads. Low thermal conductivity of the Litz wire and ferrite, and uneven distribution of the coil, and core loss cause the high temperature in the charging pads. In this paper, the loss distribution of a 50 kW three-phase WCS is investigated, and the temperature distribution is simulated using finite element analysis (FEA) considering the magnetic and non-magnetic materials of a charging pad. The thermal characteristics of an extremely high-power density 50 kW WCS prototype are tested experimentally for 10 minutes of operation. The simulation and experimental results show that the coil temperature increases to 65°C, the core temperature varies between 50°C to 150°C, and the packaging temperature increases to 65°C after 10 minutes of operation at rated 50 kW output power.

Mohammad, Mostak↗

DOE OSTI2022

Thermal analysis of RHIC arc dipole magnet cold mass with EIC beam screen

The existing RHIC storage rings – including their superconducting magnet arcs – will be used for the hadron storage ring of the Electron-Ion Collider (EIC). The vacuum chamber of these magnets was not designed for the EIC hadron beams, with shorter bunches and of higher average current than the RHIC beams. With the current stainless steel beam pipe, the resistive-wall (RW) heating will exceed the dynamic heat load budget. Limiting the RW heating is important to prevent the superconducting magnets from quenching and to maintain a low screen temperature necessary to impede the rise of RW heating (higher resistance at higher temperature) as well as to achieve desired ultra-high vacuum. In addition, simulations predict the formation of electron cloud which would further contribute to the dynamic heat load and could compromise the quality and stability of the beam. To reduce the resistive-wall heating and suppress electron cloud, a beam screen will be installed in the vacuum chamber of the RHIC SC magnets. The screen will have a high RRR copper layer at its inner face – useful to reduce the resistive-wall impedance thanks to its high conductivity especially at cryogenic temperatures – and will be coated with a thin layer of amorphous carbon, a material with low secondary electron yield to suppress the formation of electron clouds. The baseline solution envisages a screen that will be cooled by thermal contact to the 4.55 K beam pipe. Detailed thermal analysis have been conducted in ANSYS 2020 for an arc dipole cold mass equipped with a beam screen in order to study the feasibility of a passively-cooled screen and guide its design. Temperature-dependent thermal conductivity properties of all materials in the operating (cryogenic) temperature range are considered. Suitable assumptions and simplifications are made to model the magnet coil and calculate its homogenized thermal conductivity. Sensitivity studies with respect to layer thicknesses and area of contact are carried out and results are presented.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

An Engineering Prototype of a Late Stage Ionization Cooling Cell for a Muon Collider

Achieving the low emittances required for a muon collider requires ionization cooling. Much of that cooling occurs in compact cooling cells where superconducting coils and conventional RF cavities are closely interleaved. The real challenges for these cooling cells reside in their engineering challenges: high field solenoids, RF cavities, and absorbers, often designed near technological limits, placed in close proximity to each other. We thus propose to build a prototype ionization cooling cell to demonstrate the capability of constructing an ionization cooling channel reaching the lowest emittances and to provide engineering input for the design of such beamlines.

43 PARTICLE ACCELERATORS↗

NASA NTRS1972

Cryogenic gel flow viscometer

Coiled section of tubing measures viscous properties of gelled cryogenic propellants under conditions closely resembling flow in rocket engine systems. Characteristic flow curve provides data necessary for the design of prototype hardware systems using the liquid or gel of interest.

Globus, R. H.↗

NASA NTRS1981

Recent developments in mass drivers

In the past eight months a new mass driver concept has been explored through calculation and inductance model verification. It retains the linear synchronous principle and freedom from arcs, plasmas or physical contact between the accelerated bucket and accelerator. However, it discards passive magnetic flight and obtains transverse focussing from strong off-axis restoring forces produced by drive coils operating in a pull-only mode. This paper gives the reasoning on which the new concept is based, and applies the concept to a lunar catapult design.

Oneill, G. K.↗

NASA NTRS2015

Design and Testing of a Small Inductive Pulsed Plasma Thruster

The design and testing of a small inductive pulsed plasma thruster (IPPT), shown in Fig. 1 with all the major subsystems required for a thruster of this kind are described. Thrust measurements and imaging of the device operated in rep-rated mode are presented to quantify the performance envelope of the device. The small IPPT described in this paper was designed to serve as a test-bed for the pulsed gas-valves and solid-state switches required for a IPPTs. A modular design approach was used to permit future modifications and upgrades. The thruster consists of the following sub-systems: a) a multi-turn, spiral-wound acceleration coil (27 cm o.d., 10 cm i.d.) driven by a 10 microFarad capacitor and switched with a high-voltage thyristor, b) a fast pulsed gas-valve, and c.) a glow-discharge pre-ionizer (PI) circuit. The acceleration-coil circuit may be operated at voltages up to 4 kV (the thyristor limit is 4.5 kV). The device may be operated at rep-rates up to 30 Hz with the present gas-valve. Thrust measurements and imaging of the device operated in rep-rated mode will be presented. The pre-ionizer consists of a 0.3 microFarad capacitor charged to 4 kV and connected to two annular stainless-steel electrodes bounding the area of the coil-face. The 4 kV potential is held across them and when the gas is puffed in over the coil, the PI circuit is completed, and a plasma is formed. Even at the less than optimal base-pressure in the chamber (approximately 5 × 10(exp −4) torr), the PI held-off the applied voltage, and only discharged upon command. For a capacitor charge of 2 kV the peak coil current is 4.1 kA, and during this pulse a very bright discharge (much brighter than from the PI alone) was observed (see Fig. 2). Interestingly, for discharges at this charge voltage the PI was not required as the current rise rate, dI/dt, of the coil itself was sufficient to ionize the gas.

Martin, Adam K.↗

NASA NTRS2022

Development of a Deployable Opitcal Aperature

The Deployable Optical Receive Aperture (DORA),a new technology being developed jointly between JetPropulsion Laboratory (JPL) and Arizona State University(ASU), is based on deploying arrays of fast optical detectors tocreate large receive apertures and seeks to achieve gigabitconnectivity at distances of thousands of kilometers. Smallspacecraft forming the LunaNet communications network andequipped with optical communications systems, such as theproposed DORA aperture, should be able to communicate atGigabit per second rates over long distances. This data rateenhancement can allow gigabit per second connectivitybetween lunar assets (astronauts, rovers, instruments) and thelunar gateway. Under sponsorship of NASA's Small SpacecraftTechnology Program (SSTP), JPL is deploying the DORApayload and ASU is developing a 3U CubeSat for a follow-onlow-Earth-orbit (LEO) mission to demonstrate DORA'scapabilities. The basic DORA payload consists of 5 receiverpanels, a transmitting telescope and processing units. Eachreceiver panel contains dozens of power-combined detectors tomimic a large optical aperture. The total receive aperture ofDORA is provided by the sum of the effective detecting area ofthe 5 panels. The transmit telescope includes a 200mW, 850nmlaser and a voice-coil fast steering mirror (FSM). The resultingDORA terminal should be able to provide duplex connectivityat rates up to 1 gigabit per second at the distances of interest.We have designed the entire DORA payload and plan topresent the test results of our DORA engineering model. Theseresults include angle-of-arrival, data rate and bit error ratemeasurements.

Yi, Lin↗

DOE OSTI2023

Pulsed Power Supply for Magnet Quench Training

Superconducting magnets typically go through aseries of spontaneous “training” quenches as their current isincreased towards its design value. To decrease the number ofthese quenches, a device has been designed to boost the magnetcurrent at the moment a quench has been detected and beforemagnet protection has been initiated. The aim of the boost is todrive the magnet coil further along towards its maximum currentwith each training quench, and hence reduce the number ofquenches required.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Regal Beloit Final Technical Report

The original project proposal submitted from NovaTorque Inc (NovaTorque) in 2016 was to improve the existing motor with 95% efficiency by reducing the losses by 21% to achieve 96%. A few months after the proposal was submitted, NovaTorque lost funding and went out of business. The assets of NovaTorque were then acquired by Regal Beloit Corporation (“Regal Beloit” or “Regal”). When the NovaTorque proposal was selected, the project was transferred to Regal Beloit. Once we had production samples from the new Regal production line, they were tested at the Regal Beloit test lab in Wausau, WI. The original NovaTorque motor had an efficiency of 95%, but when the technology was transferred to Regal Beloit, there were multiple manufacturing improvements made, even though the basic electromagnetic design did not change. The test results in Wausau showed that the motors made at the Regal Beloit plant had an efficiency of 96%. Since the goal of the project was to reduce the losses by 21%, a new efficiency target of 96.8% became the project objective. In the first budget period, motors were tested to get the baseline performance. We then used FEA modeling with ANSYS Maxwell to model the existing motor to get correlation between the FEA simulations and the actual test results. Once the model was validated, we evaluated some changes that could be made to the stator to reduce the losses and improve efficiency without changing the rotor or stator housing, keeping the modifications easy to implement. The changes were primarily in the area of making the stator axially shorter and adding Soft Magnetic Composite (SMC) tooth tips. In the second budget period, we proceeded to design and build the new stator that was identified above and identified additional improvements in the process that included a stator machining modification and the use of rectangular wire. When we actually built the motor, the choice of rectangular wire turned out to be a problem. The wire was made by squishing round wire to get the rectangular shape, which caused work hardening, making the wire too stiff to make the desired coils. We shifted to annealed square wire which was better, but we still could not maintain the proper coil envelope. The result was that we had reduced cross section area for stator laminations. We also had to have a radial offset resulting in a radial misalignment between the stator and rotor because of the oversized coils. After the motor was completed, it was shipped to Texas A&M University for testing. With the loss of flux from these issues, the measured motor efficiency was only 96.3%. The primary focus of this motor was to make sure our FEA simulation model predicted the measured losses and overall efficiency, this we moved on to the FEA simulation. The FEA simulations of the motor “as built” with misalignments had good correlation with the test results, so the next step was to use that model to optimize the design of the motor for a final build. This time we considered changes to the stator and rotor and also minor changes to the housing diameter. In the third budget period, we did the detailed design and construction of the final prototypes. The final prototypes had a slight increase in the stator diameter to fit in a standard Regal Beloit housing. We shortened the stator and use more layers of wire in the coils. We also increased the cone angle of the rotor and stator from the original 110 degrees to 130 degrees to get some additional efficiency and optimized the stator cross section. The predicted efficiency from the FEA simulations was 96.9%. When completed, the motors were tested. We were a little short of reaching our target efficiency goal of 96.8%. We were only able to get to 96.7% efficiency. While it may be possible with additional iterations in designs and future builds to gain that additional 0.1%, we believe that we are close to the best we can achieve from a practical viewpoint, and additional iterations would be more work than the potential gains would be worth. No other motor in this class can even reach the 96% that we started with.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Raising the Bar in High Performance Laboratory Design

Laboratory facilities are expensive to build and operate, they consume energy at high rates compared to other types of buildings, and modifications are frequently required to accommodate ever-changing research activities. PNNL sought ways to address these issues in the design and construction of a 14,700 sq. ft. new laboratory building. To improve adaptability to change a high roof structure was used that allows raising the ceiling when needed with minimal disruption to installed HVAC and electrical utilities. Also, HVAC equipment was located on a mezzanine above the central corridor rather than above ceilings. This eliminates the need for maintenance personnel to routinely access lab spaces, reducing disruption to research staff and improving maintenance access. To improve the reliability of operations while reducing energy consumption, heat pipe heat recovery with evaporative cooling, zoned heating/cooling coils, high-efficiency condensing boilers, district cooling, VAV fume hoods, DDC controls, energy use monitoring, and implementation of the US Department of Energy’s Guiding Principles for Federal Leadership in Sustainable Buildings were all used. The energy model developed during design projected energy use at 2,840 MBtu/yr, a 13.5% savings over ASHRAE Standard 90.1-2010. The first full year of operation resulted in actual energy use of 2,661 MBtu, a savings of 19% over Standard 90.1. As a result of the project design’s demonstrated success, these strategies will be incorporated into a significantly larger (125,000 sq ft), $65 million lab facility to be constructed on the PNNL campus in 2020.

Scott, Jeffery M.↗

DOE OSTI2024

Getting to the bottom of it: do laser-driven coils really work? (Final Technical Report)

Since claims of ultra-high (up to ~ 1.5 kiloTesla) magnetic fields appeared in the scientific literature, it became necessary to conduct controlled experiments to determine the validity of these claims and assess the real capability of laser-driven coils (LDCs) to produce high B-field to be used in HEDP (high energy density physics) experiments. This project assessed the viability of generating magnetic fields using LDCs. This was accomplished with a thorough analysis of several focused experiments on the OMEGA EP laser at LLE designed to measure the magnetic field inside LDCs. We demonstrated how problems with prior diagnostic analyses have led to overestimations of the magnetic fields generated from LDCs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗