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DOE OSTI2025

In Situ MOF Pyrolysis Construction of Hierarchical Porous Co‐Nanoparticles/Carbon Cloth Composites for Enhanced Electromagnetic Wave Shielding and Absorption

The development of high-performance electromagnetic protection materials integrating broadband absorption and effective shielding capabilities is hindered by challenges in simultaneously optimizing multiple electromagnetic properties through conventional material designs. This study pioneers a hierarchical porous Co nanoparticle/carbon cloth (Co/CC) composite via controlled annealing of a Co-MOF precursor on carbon cloth. The Co-MOF served a dual role as both magnetic source and pore-forming agent, enabling in situ generation of uniformly dispersed Co nanoparticles and creation of abundant pores/interfaces on the CC fibers during pyrolysis. This unique architecture synergistically enhanced dielectric loss (via interfacial/dipolar polarization) and magnetic loss (via natural resonance, exchange interactions, and eddy currents), significantly improving impedance matching. The hierarchical pores further functioned as integrated “absorption–reflection” units for efficient electromagnetic energy attenuation. Consequently, the Co/CC composite annealed at 800°C (Co/CC-800) achieves minimum reflection loss (−40.69 dB) and 120% effective absorption bandwidth extension (6.16 GHz) as a filler, and exhibits superior electromagnetic interference shielding effectiveness (46.66 dB) as an integrated component. Significantly, Co/CC-800 demonstrated robust photothermal and electrothermal conversion capabilities, ensuring operational stability in ice-covered and humid harsh environments. This work pioneers a pore-structure-mediated strategy to harmonize dielectric–magnetic synergy, providing a new paradigm for designing advanced multifunctional electromagnetic protection materials.

dielectric‐magnetic synergy↗

DOE OSTI2023

The Addition of Boron to Melt-Spun Fe-6.5%Si Ribbons

Fe-6.5%Si has higher electrical resistivity, lower magnetocrystalline anisotropy, and lower magnetostriction than traditional Fe-3.2%Si silicon steel. The reduced iron losses of Fe-6.5%Si render it a highly favorable candidate for high-speed motors and transformers. However, large-scale production of wide Fe-6.5%Si tape by rapid solidification can be challenging mainly because of its high melting point. In this work, boron is alloyed to Fe-6.5%Si to reduce its melting temperature and interfacial energy to improve the alloy’s processability. Boron additions from 0.01 wt.% to 2.24 wt.% into Fe-6.5%Si and its effect on ribbon thickness, grain size, magnetic, and mechanical properties were studied. Further, minor boron alloying significantly changed the melt pool stability and wetting on the quench wheel and in turn increased the quench rate with minimum impact on the magnetic saturation and ductility. Boron addition of < 0.06 wt.% was also found beneficial to the magnetic property of the alloy by lowering both its hysteresis and eddy current losses.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Structural modeling and validation of laminated stacks in magnetic gearing applications

Laminated structures are commonly employed in magnetic gears based on their ability to direct magnetic flux, while inhibiting eddy currents. Unfortunately, the stiffness of the laminated structure is much lower than a solid part, which can lead to unacceptable deflections, given the large magnetic forces and small air gaps in magnetic gears. Finite element analysis of laminations to accurately predict these deflections can be computationally expensive due to the small elements needed to model the thin lamination dimensions. These analyses also have some uncertainty due to the assignment of bonding stiffness. This paper presents a means of accurately modelling the deflection of a laminated stack with reduced complexity and computational time, which is compared to experimental results. Here, the resulting methods are then used to assess the magnetic and mechanical advantages of different designs for the modulating pieces of a magnetic gear.

42 ENGINEERING↗

DOE OSTI2021

Active control of resistive wall mode via modification of external tearing index

Modification of the external tearing index, Δ ext ′ , by magnetic feedback is analytically investigated for the purpose of controlling the resistive plasma resistive wall mode (RP-RWM). The matching method is pursued by deriving expressions for the close-loop Δ ext ′ and by linking it to the counterpart from the inner layer. Various feedback coil configurations are found to generally reduce Δ ext ′ and stabilize the RWM, with either proportional or derivative control. Feedback modification of Δ ext ′ is found to be generally independent of the inner layer resistive interchange index D R , confirming that feedback action primarily modifies the solution in the outer ideal region for the RP-RWM. Exception occurs when either the inner layer favorable curvature effect becomes sufficiently large or the feedback action is sufficiently strong to introduce a rotating RP-RWM in the static plasma, leading to complex-valued close-loop Δ ext ′ . The perturbed magnetic energy dissipation in the outer region, associated with the eddy current in the resistive wall, is identified as the key physics reason for feedback induced complex Δ ext ′ . Similar results are also obtained for active control of the external kink instability, whose open-loop growth rate is significantly reduced by inclusion of the plasma resistivity. Within the single poloidal harmonic approximation, which is most suitable for the matching approach, external active coils combined with poloidal sensors are often found to be more efficient for feedback stabilization of the mode at large proportional gain values. This counter-intuitive result is explained as the lack of (non-resonant) poloidal harmonics for proper description of the feedback coil geometry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Analysis of Dynamic Behavior of the Target and the Deuterium-Tritium Ice in Magnetic-Field Assisted Implosions

The use of strong magnetic fields to augment the output energy of inertial confinement fusion experiments at the National Ignition Facility is of high interest. It offers the potential of reducing electron thermal conduction and increasing hot-spot alpha heating with little to no change in hohlraum behavior. In these magnetically assisted ignition experiments, the ultimate goal is to add a B-field in the form of a pulse ranging from 25 to 60 T to a high-performing hohlraum implosion several microseconds before impingement of the laser beams. This requires eliminating metallic components in the target and replacing them with electrically nonconducting materials. However, the strong eddy currents generated by the rapidly increasing high B-field, which were calculated to be as high as 2000 K, can heat the hohlraum. Here in this paper, we examine the transient effects of this rapid temperature change on the behavior of the target as well as the fuel layer composed typically of deuterium and tritium. Using simulations and calculations for limiting case scenarios, we find that the effect of the heating is not restrictive toward the performance of the target or the quality of the deuterium-tritium ice.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Kinetic equilibrium reconstructions of plasmas in the MAST database and preparation for reconstruction of the first plasmas in MAST upgrade

Reconstructions of plasma equilibria using magnetic sensors were routine during operation of the Mega Ampere Spherical Tokamak (MAST) device, but reconstructions using kinetic profiles were not. These are necessary for stability and disruption analysis of the MAST database, as well as for operation in the upgrade to the device, MAST-U. The three-dimensional (3D) code VALEN is used to determine eddy currents in the 3D vessel structures for vacuum coil test shots, which are then mapped to effective resistances in the two-dimensional vessel groupings in the EFIT equilibrium reconstruction code to be used in conjunction with nearby loop voltage measurements for estimated currents in the structures during reconstruction. Kinetic equilibrium reconstructions with EFIT, using all available magnetic sensors as well as Thomson scattering measurements of electron temperature and density, charge exchange recombination spectroscopy measurements of ion temperature, and internal magnetic field pitch angle measurements from a motional Stark effect (MSE) diagnostic are performed for a large database of MAST discharges. Excellent convergence errors are obtained for the portions of the discharges where the stored energy was not too low, and it is found that reconstructions performed with temperature and density measurements but without MSE data usually already match the pitch angle measurements well. A database of 275 kinetic equilibria is used to test the ideal MHD stability calculation capability for MAST. In conclusion, the necessary changes to conducting structure in VALEN, and diagnostic setup in EFIT have been completed for the upgrade from MAST to MAST-U, enabling kinetic reconstructions to commence from the first plasma discharges of the upgraded device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Numerical investigation of active control of tearing mode by magnetic coils and the role of Δ'

Magnetic feedback stabilization of the tearing mode (TM) is numerically investigated, utilizing the MARS-F code (Liu et al 2000 Phys. Plasmas 7 3681) for toroidal tokamak equilibria. With control coil configurations assumed in this study, magnetic feedback partially or fully stabilizes the TM, with either vanishing or finite equilibrium pressure. The best control is achieved by the combination of internal active coils and internal poloidal sensors. The internal and external tearing indices are evaluated for the close-loop system, based on the MARS-F computed mode eigenvalue and eigenfunction, respectively. In the absence of the favorable curvature effect, these two indices are real-valued and quantitatively agree well with each other. For the equilibrium with finite pressure gradient at the mode rational surface, the favorable average curvature effect becomes important and the close-loop tearing index also becomes complex-valued, partly due to interaction of the feedback system with the dissipative wall eddy current response. Isolating the inner layer and outer region response to magnetic feedback, with either proportional or proportional-derivative actions, allows to establish that feedback stabilization of the TM occurs mainly due to modification of the behavior of the external ideal solution, further confirming the analytic result reported in He et al 2021 Phys. Plasmas 28 012504.

Physics↗

DOE OSTI2024

Non-linear MHD modelling of transients in tokamaks: a review of recent advances with the JOREK code

Transient magneto-hydrodynamic (MHD) events like edge localized modes (ELMs) or disruptions are a concern for magnetic confinement fusion power plants. Research with the MHD code JOREK towards understanding control of such instabilities is reviewed here in a concise way to provide a complete overview, while we refer to the original publications for details. Experimental validation for unmitigated vertical displacement events progressed. The mechanism of vertical force mitigation by impurity injection was identified. Two-way eddy current coupling to CARIDDI was completed. Shattered pellet injection was simulated in JET, KSTAR, ASDEX Upgrade (AUG) and ITER. Benign runaway electron beam termination in JET and ITER was studied. Coupling of kinetic REs to the MHD is ongoing and a virtual RE synchrotron radiation diagnostic was developed. Regarding pedestal physics, regimes devoid of large ELMs in AUG were simulated and predictive JT60-SA simulations are ongoing. For ELM suppression by resonant magnetic perturbations (RMPs), AUG, ITER and EAST simulations were performed. A free boundary RMP model was validated against experiments. Evidence for penetrated magnetic islands at the pedestal top based on AUG experiments and simulations was found. Simulations of the naturally ELM-free quiescent H-mode in AUG and HL-3 show external kink mode formation prevents pedestal build-up towards an ELM within windows of the edge safety factor. With kinetic neutral particles, high field side high density formation in ITER was simulated and with kinetic impurities, tungsten transport in AUG RMP plasmas was studied. To capture turbulent transport, electro-static full-f particle in cell models for ion temperature gradient and trapped electron modes were established and benchmarked. Application to RMP plasmas shows enhanced turbulence in comparison to unperturbed states. Energetic particle interactions with MHD were studied. Flux pumping that prevents the safety factor on axis from dropping below unity was simulated. First non-linear stellarator applications include current relaxation in $l$ = 2 stellarators, while verification for advanced stellarators progresses.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

On the Impact of High-Order Harmonic Generation in Electrical Distribution Systems

The modern power grid has seen a rise in the integration of non-linear loads, presenting a significant concern for operators. These loads introduce unwanted harmonics, leading to potential issues such as overheating and improper functioning of circuit breakers. In pursuing a more sustainable grid, the adoption of electric vehicles (EVs) and photovoltaic (PV) systems in residential networks has increased. Understanding and examining the effects of high-order harmonic frequencies beyond $1.5$ kHz is crucial to understanding their impact on the operation and planning of electrical distribution systems under varying nonlinear loading conditions. This study investigates a diverse set of critical power electronic loads within a household modeled using PSCAD/EMTdc, analyzing their unique harmonic spectra. This information is utilized to run the time-series harmonic analysis program in OpenDSS on a modified IEEE 34 bus test system model. The impact of high-order harmonics is quantified using metrics that evaluate total harmonic distortion (THD), transformer harmonic-driven eddy current loss component, and propagation of harmonics from the source to the substation transformer.

Peerzada, Aaqib A. [BATTELLE (PACIFIC NW LAB)]↗

DOE OSTI2024

Polyphase Rotary Transformer for Field Excitation of Electric Machines

This paper presents the magnetic design of a high-frequency three-phase rotary transformer for Wound Rotor Synchronous Motors (WRSM). The traditional DC field excitation of the WRSM is highly challenging as it relies on the brushed connection. The brush/slipring-based connections need cooling, sealing and prone to wear and tear requiring regular maintenance. The proposed three-phase rotary transformer replaces the traditional brushed excitation by a high-power density polyphase wireless excitation. Furthermore, compared to a traditional single-phase rotary transformer, the proposed three-phase rotary transformer significantly enhances the power density, and reduces the eddy current losses and the output voltage ripples.

Aydin, Emrullah↗

DOE OSTI2024

Evaluation of Autonomous Vehicle Sensing and Compute Load on a Chassis Dynamometer

The sensing and compute load auxiliary energy consumption in autonomous vehicles may be significant due to the large number of sensors and the high compute load from sensor processing and route planning. To understand this issue, this study investigates the top-down energy usage of an electric 2015 Kia Soul fully instrumented with state sensors and a state-specific computer for path planning and sensor processing. A chassis dynamometer was then used to evaluate the cases of (1) no sensors or computation, (2) only sensors operating, and (3) sensors plus compute load. The vehicle was operated autonomously on the dynamometer using a PolySync drive-kit with drive-by-wire longitudinal control. The DynoJet model 224xLC was used to adapt the eddy current dynamometer's road load parameters to comply with an Environmental Protection Agency drive schedule and to evaluate performance against the Argonne National Laboratory Digital Dynamometer Dataset. On the UDDS-HWFET combined driving cycle, the stock battery's range was reduced by 5.6% for sensors alone and 12.2% for sensors and compute load. These results show that the added sensing and compute auxiliary load from automated and autonomous systems is significant and that research efforts need to be spent investigating new energy efficient systems.

Brown, Nicholas E.↗

DOE OSTI2023

Experiments to Quantify the Shielding Efficacy of Materials to be Implemented for Portable Shielding Enclosures that Adequately Mitigate EMI from Lighting Attachment Events

Mitigating electric and magnetic fields induced by lightning strike events is critical for the security and longevity of electrical components. Electromagnetic interference originating from a lightning strike is categorized into the low to medium frequency ranges, commonly referred to as the “magnetic coupling” regime. This low-frequency characteristic brings about the problem of shielding magnetic flux lines. Such shielding can be accomplished with highly conductive materials via the generation of eddy currents or by diverting the flux lines using materials with a large relative permeability. The shielding effectiveness of materials with varying thicknesses and geometry are tested using a pulse forming network having comparable characteristics to a scaled lighting strike. A four-stage Marx generator with a peak current of ~33 kA and a risetime of 1.4 μs is used as the pulse forming network to emulate the scaled electric and magnetic fields. The data collected from these experiments provide information and techniques that can be implemented into the design of a portable, deployable shielding enclosure.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2022

A Prototype High-Voltage Pulsed Power Supply for Control of the ITER Shattered Pellet Injection System Flyer Plate Valve

A high-voltage pulsed power supply (HVPPS) has been designed, prototyped, and tested for driving an eddy current actuated propellant valve for the International Thermonuclear Experimental Reactor (ITER) disruption mitigation system. The high-voltage (HV) dc supply output voltage is software programmable, and the energy storage capacitor bank can be readily reconfigured as 200, 400, 600, and 800 μ F, enabling testing and optimization of both the valve drive and valve systems. Multiple system parameters are monitored before, during, and after each firing of the valve. The system parameters are both displayed and stored for further analysis. Control of the setup, firing sequence, and data collection is automated using a LabVIEW-based control program. The programmability and reconfigurability of this system collectively provide a flexible and robust platform for system refinement and optimization. In this article, a summary of the system will be provided including operational sequences, HV switching and associated triggering methods and circuits, and results measured while firing a solid frozen pellet. Additionally, planned refinement activities toward meeting all requirements for ITER integration will be discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Electromagnetic Analysis of ITER Electron Cyclotron Emission Model

The ITER electron cyclotron emission (ECE) diagnostic system is located at diagnostics shielding module 2 (DSM2), equatorial port 9 (EP9), to measure electron temperature profile and electron temperature fluctuations, and also assess nonthermal electron distributions via the oblique view. Therefore, ECE has both radial and oblique views with two hot sources for calibration and two couples of mirrors for two different optical views. It shall receive that the large electromagnetic (EM) loads up to 100-MN/m3 force density due to the eddy currents on the copper mirrors generated by the short transient plasma disruption. The simplified EM analysis model using magnetic field ( B ) data and flux variations (dB/dt) method based on the worst case of plasma disruption, MD_DW_EXP16MS_CATIII, has been developed to calculate the force and moments for each ECE component and support structure for EP9 DSM2 Bay2 and Bay3. The B and dB/dt methods use the constant B and dB/dt assumed for each local bay space, but the real B and dB/dt are basically varied along the radial direction of each bay. The complex global model with the local ECE components and support structure using Maxwell transient has been developed to do EM analysis to compare the results of the B and dB/dt models. The volumetric EM force density of the whole ECE components and support structure can be used for the subsequent structural analysis. In conclusion, combined with the thermal and nuclear loads and seismic and initial loads, the ECE integration analysis can be finalized for the operation case.

Fang, J. [Princeton Plasma Physics Laboratory (PPP↗

DOE OSTI2024

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗

DOE OSTI2021

Aspenplus Model For Msw Sorting Process

Unit operations for the MSW sorting process include shredding, magnets for ferrous separation, screening, air classification, eddy current for non-ferrous separation, and near-infrared detection for plastic recovery. The MIXCINC module within Aspen Plus was selected to handle mixed solid streams containing inert (metals and glass) and non-conventional materials (paper, plastics, biomass, organic waste). The Peng-Robinson equation of state with Boston-Mathias modifications was applied to predict properties for a nonconventional solids mix. Enthalpy and density of the non-conventional materials were defined using non-conventional material properties.

Hu, Hongqiang↗

DOE OSTI2021

Development of High Bs Fe-Ni Based Metal Amorphous Nanocomposite by Optimization of Glass Forming Ability

A growing interest in electric vehicles challenges soft magnetic materials to improve efficiency and power density. Metal amorphous nanocomposites (MANCs) have lower coercivities and eddy current losses, allowing for greater efficiency and higher switching frequency. The later allows for high motor speeds and improved power density. However, commercially available and laboratory demonstrated MANCs have shortcomings. Fe-based MANCs, such as FINEMET have excellent magnetic properties, but mechanical properties limit their application in high speed electric motors (HSMs). Fe-Co based MANCs, such as HITPERM, have high saturation inductions and good mechanical properties, but elevated magnetostrictive losses. Co-based MANCs and more recent Fe-Ni based MANCs have low losses and good mechanical properties, but lower saturation inductions (1-1.2 T), that limit power density in HSMs. Recently, much work has explored improving saturation induction in MANCs by increasing the content of magnetic elements, which comes at the cost of glass-forming ability (GFA). These efforts where generally limited to trial and error testing. Additionally, all work to date has focused on Fe-based alloys. In this work, a method of using Thermocalc simulation to locate near-eutectic compositions has been applied to Fe-Ni based alloys. Minima in liquidus temperature and solidification range were found for a ternary composition range and used to identify compositions that retain good GFA as the percentage of magnetic elements is increased. The (Fe 70 Ni 30 ) x (B-Si-Nb) 100-x alloy system for x=82% and x=85% was explored by Thermocalc simulations. This is an increase in magnetic element content compared to previously developed x=80% alloys. 3 compositions in the x=82% system, and 1 alloy in the x=85% system where identified and successfully cast as amorphous ribbon. The amorphous nature of the ribbon was confirmed by a bend test and XRD. Magnetic testing was performed by PPMS to measure saturation induction and Curie temperature of the amorphous material. The Curie temperatures increased to 407-438 °C for the x=82% alloys, and 462 °C for the x=85% alloy. Saturation induction increased to 1.28-1.36 T for the x=82% alloy and 1.48 T for the x=85% alloy, which is a significant improvement over the ~370 °C Curie temperature and 1.2 T saturation of previous Fe-Ni alloy. Crystallization behavior was studied by XRD for the x=85% alloy, showing that crystallization process follows a 2-step process of Amorphous → BCC+FCC+Amorphous → BCC+FCC+Fe 3 B+Fe 23 B 6 . Post annealing magnetic properties were studied by strip testing, and saturation induction as high as 1.48 T was seen after optimal annealing. TEM was used to study structure of as cast and annealed material. 2 alloys with x=82% compositions were identified with an optimal crystalline size of 10-20 nm, while the x=85% alloy had this structure in the as cast state. This opens the possibility of using the alloy in the as cast state, without requiring annealing. In conclusion, alloys with good GFA and improved magnetic properties were identified by Thermocalc simulation.

Krimer, Yuval↗

DOE OSTI2021

NDT System for Metal Components in Concrete Structures

The goal of this SBIR program is to develop new NDT technology based on the innovative use of magnetic sensors designed specifically for ECT (Eddy Current Testing) of steel reinforcements in concrete structures. The Phase IIA goal is to expand the R&D accomplished in Phase II, such that the probe system is more capable, and the inspection system is more flexible.

42 ENGINEERING↗