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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Micro-photoluminescence mapping and Chemometrics for the rapid classification of rare earth materials

This article introduces advancements in chemically mapping rare earth materials using photoluminescence (PL) and chemometrics. By leveraging the high sensitivity and selectivity of PL compared to alternative optical techniques, as well as its compatibility with microscopy, we present enhanced capabilities for noninvasive material screening and characterization. Exemplary PL spectra of samarium(III) and europium(III) in oxide, nitrate, and chloride forms demonstrated the ability to extract detailed chemical information of diverse rare earth particles. Additionally, we introduced efficient PL mapping sequences capable of covering a 9 mm diameter carbon tab within minutes, which highlighted the benefits of rapid, large-area imaging. Furthermore, an integrated approach combining PL mapping with principal component analysis and a random forest classifier enabled the resolution of overlapping spectral peaks from different chemistries and provided accurate material classification. In conclusion, these advancements underscored the versatility and robustness of PL for chemically mapping rare earth materials, with the potential to support applications in mining, energy, environmental monitoring, isotope production and beyond.

Chemometrics↗
DOE OSTI2017

Alternative High-Performance Motors with Non-Rare Earth Materials, Final Publishable Report

Electric drive systems, which include electric machines and power electronics, are a key enabling technology for advanced vehicle propulsion systems that reduce the petroleum dependence of the transportation sector. To have significant effect, electric drive technologies must be economical in terms of cost, weight, and size while meeting performance and reliability expectations. The goal of the project is to develop traction motors that reduce or eliminate the use of rare-earth materials and meet the DoE specifications for such a traction motor. This is accomplished by evaluating and developing multiple motor topologies in conjunction with advanced materials. Eight non-permanent magnet motor topologies and two reduced or non-rare earth motor topologies are analyzed and compared using a common set of requirements. Five of the motors are built and tested to validate the analysis. This paper provides a detailed quantitative comparison of the different machine topologies that reduce or eliminate rare-earth materials. Conclusions are drawn from the analysis and test data to show the tradeoffs related to selecting each of the motor topologies with the hope of providing practicing engineers and researchers in the field enough guidelines for choosing the “optimum” machine topology that suits their applications and set of performance requirements. Four materials technologies were investigated for their ability to enable a reduced rare earth electric motor. Two of the technologies were soft magnetic materials, one was a non-rare-earth containing permanent magnet technology, and the last was an insulation material. These processing and performance of these materials were first demonstrated in small coupons. The coupon tests justified proceeding to larger scale processing for two of the materials technologies: 1) a dual-phase soft magnetic material for use in rotor laminates and 2) a high temperature insulation material for use as a slot liner in the stator. The dual phase soft magnetic material was produced at a scale sufficient to build and test a sub-scale motor prototype. The high temperature insulation material was first evaluated in a series of “statorettes” before being demonstrated in the stator of one of the full-scale motor prototypes. Testing of the dual phase material revealed issues with process variability in larger production volumes that are being addressed in a subsequent project. The performance of the high-temperature slot liner insulation was demonstrated during the operation of a full-scale prototype. Furthermore, the insulation material was shown to survive aging tests of 2000 hours and 280 °C and 800 hours at 300 °C. This program provides analysis and data to accelerate the introduction of hybrid electric vehicles into the U.S. road vehicle fleet and bring the added benefits of reduced fuel consumption and environmental impacts

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Design of High Power Density 100 kW Surface Permanent Magnet Machine with No Heavy Rare Earth Material Using Current Source Inverter for Traction Application

Surface permanent magnet (SPM) machines are appealing candidates for traction applications because of high power density and high efficiency. Rare-earth magnets deliver high performance but raise concerns about material supply dependability, particularly if they use heavy rare-earth materials. This paper presents the design of a high-performance SPM machine without any heavy rare-earth material that is optimized specifically for a current-source inverter (CSI) traction drive. This machine is designed for a constant-power speed ratio (CPSR) of 3. A genetic algorithm has been performed to achieve a target of 50 kW/L active power density at speeds up to 20,000 rpm. Operation at a peak line-to-line voltage of 800 V can be achieved using 1200 V power devices with a safety margin. The predicted electromagnetic and rotor structural performance characteristics are presented using both analytical and finite element analysis (FEA) results.

(CPSR)↗
DOE OSTI2017

Enhancing Magnetic Functionality with Scandium: Breaking Stereotypes in the Design of Rare Earth Materials

Replacement of strongly magnetic gadolinium with weakly magnetic scandium unexpectedly enhances ferromagnetic interactions in (Gd 1–x Sc x ) 5 Ge 4 . Based upon this counterintuitive experimental finding we demonstrate the unique role 3d 1 electrons of scandium atoms play in mediating magnetic interactions between the gadolinium atoms from the neighboring layers in the Sm 5 Ge 4 -type crystal lattice. Scandium substitutions at and below 20% rapidly increase the Curie temperature, TC, of the Gd 5 Ge 4 parent, eliminate both the kinetic arrest and hysteresis, and drastically improve reversibility of the first-order magnetostructural transformation at T C . In agreement with first-principles predictions, higher than 20% Sc leads to the formation of a closely related Pu 5 Rh 4 -type structure where the first-order magnetostructural transformation is replaced by a conventional second-order ferromagnetic ordering that remains accompanied by a continuous rearrangement of the crystal lattice. In conclusion, comparison of two materials with similar structures and compositions shows that significantly stronger magnetocaloric effect occurs in the first-order material, which also shows very small hysteresis. Furthermore, we demonstrate that a behavior of a specific interatomic distance can predict anomalous physical properties in a series of alloys where compositional dependence of lattice parameters suggests a rather trivial solid solubility and uninteresting magnetism.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Process for recycling rare earth magnets

A method to separate rare earth material from a rare earth magnet. At least one embodiment comprises a method that heats a provided rare earth magnet to at least 600° C. whereby the rare earth magnet absorbs a dry gas. Separated rare earth materials are created. Magnetic rare earth materials are produced from the separated rare earth materials.

Tripathy, Prahbat K.↗
DOE OSTI2017

RE Light Re Mix

The RE Light process is a process that recycles fluorescent lamps for their rare earth and mercury. There is a limited U.S. market for recycled rare earth materials and current rare earth prices make domestic production cost-prohibitive.

36 MATERIALS SCIENCE↗
DOE OSTI2014

A Lightweight, Direct-Drive, Fully Superconducting Generator for Large Wind Turbines

The current trend in the offshore wind turbine industry favors direct-drive generators based on permanent magnets, as they allow for a simple and reliable drivetrain without a gearbox. These generators, however, do not scale very well to high power levels beneficial for offshore wind, and their use in wind turbines over 6 MW is questionable in terms of mass and economic feasibility. Moreover, rare earth materials composing the permanent magnets are becoming less available, more costly and potentially unavailable in the foreseeable future. A stated goal of the DOE is a critical materials strategy that pursues the development of substitute materials and technology for rare earth materials to improve supply chain flexibility and meet the needs of the clean energy economy.Therefore, alternative solutions are needed, in terms of both favorable up-scaling and minimizing or eliminating the use of permanent magnets. The generator design presented in this document addresses both these issues with the development of a fully superconducting generator (FSG) with unprecedented high specific torque. A full-scale, 10-MW, 10-rpm generator will weigh less about 150 metric tons, compared to 300 metric tons for an equivalent direct-drive, permanent magnet generator. The developed concept does not use any rare earth materials in its critical drive components, but rather relies on a superconductor composed of mainly magnesium and boron (MgB2), both of which are in abundant supply from multiple global sources.

17 WIND ENERGY↗
DOE OSTI2016

Rare earth-doped materials with enhanced thermoelectric figure of merit

A thermoelectric material and a thermoelectric converter using this material. The thermoelectric material has a first component including a semiconductor material and a second component including a rare earth material included in the first component to thereby increase a figure of merit of a composite of the semiconductor material and the rare earth material relative to a figure of merit of the semiconductor material. The thermoelectric converter has a p-type thermoelectric material and a n-type thermoelectric material. At least one of the p-type thermoelectric material and the n-type thermoelectric material includes a rare earth material in at least one of the p-type thermoelectric material or the n-type thermoelectric material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Ultrawide Temperature Range Super-Invar Behavior of R 2 (Fe,Co) 17 Materials ( R = Rare Earth)

Super Invar (SIV), i.e., zero thermal expansion of metallic materials underpinned by magnetic ordering, is of great practical merit for a wide range of high precision engineering. However, the relatively narrow temperature window of SIV in most materials restricts its potential applications in many critical fields. Here, we demonstrate the controlled design of thermal expansion in a family of R 2 (Fe,Co) 17 materials (R=rare Earth). We find that adjusting the Fe-Co content tunes the thermal expansion behavior and its optimization leads to a record-wide SIV with good cyclic stability from 3–461 K, almost twice the range of currently known SIV. In situ neutron diffraction, Mössbauer spectra and first-principles calculations reveal the 3d bonding state transition of the Fe-sublattice favors extra lattice stress upon magnetic ordering. On the other hand, Co content induces a dramatic enhancement of the internal molecular field, which can be manipulated to achieve “ultrawide” SIV over broad temperature, composition and magnetic field windows. Furthermore, these findings pave the way for exploiting thermal-expansion-control engineering and related functional materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Advanced Manufacturing of Alpha Double Prime Iron Nitride (ADPIN): An Innovative Rare Earth Element (REE) Free Ultra-High Performance Permanent Magnet for Clean Energy Applications

Iron nitride magnets offer the potential for large magnetic remanence magnets absent any rare earth materials [1]. This project was submitted in response to the funding opportunity announcement (FOA) from the Advanced Manufacturing Office (AMO) of the Office of Energy Efficiency & Renewable Energy (EERE) of the Department of Energy (DOE): DE-FOA-0001465: Advanced Manufacturing Projects for Emerging Research Exploration; Topic Area 1: Advanced Materials; Subtopic 1.1: Innovative Advanced Materials Manufacturing for Clean Energy to explore nitriding iron powder using a fluidized bed technique which if successful would accomplish nitriding the iron powder with reduce industrial energy intensity. Of particular concern when using metal powders at high temperatures in a fluidized bed reactor is the defluidization temperature of the bed, also known as the ‘bed collapse’ temperature. Above the defluidization temperature the metal powders can no longer fluidize and instead become an undesirable packed powder bed. Using the published results from the Institute of Process Engineering at the Chinese Academy of Sciences in Beijing, China, FeNix Magnetics was able to develop a spreadsheet calculation that allowed predictive guidelines for the defluidization temperature of iron powder based on the type of carrier gas, flow rate of the carrier gas, and the iron powder diameter. FeNix Magnetics was not able to conclude whether the temperatures to avoid bed defluidization that were achievable in a fluidized bed reactor actually resulted in nitriding the iron powder to the required level. In order to measure the amount of nitrogen in the iron powder, FeNix Magnetics contracted with the DOE sponsored Advanced Photon Source (APS) at Argonne National Laboratory to conduct X-Ray diffraction measurements. Unfortunately, due to COVID-19 restrictions, the DOE sponsored APS was closed and unable to provide X-Ray Diffraction measurements during this program.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High Speed Hybrid Reluctance Motor Utilizing Anisotropic Materials

With high cost and volatility driving continued efforts to decrease reliance on the critical heavy rare earth materials used in traction drive applications, General Motors developed three variants of heavy rare earth-free (HRE-free) electric motors. The variants focused on taking advantage of advanced magnet technologies and new rotor topologies to improve mechanical strength and achieve power targets. The three variants were a HRE-free permanent magnet reluctance motor, a synchronous reluctance motor utilizing small HRE-free permanent magnets, and an induction motor with inserted copper bars and cast aluminum end-rings. Motors were designed with the intent of primary or secondary traction applications, depending on the topology. Variant 1 achieved performance comparable to HRE-containing permanent magnet motors through optimized topology and validation of HRE-free magnets, focusing on achieving energy products and demagnetization resistance comparable to those of HRE-containing magnets. Demagnetization testing demonstrated the motor robustness to currents and temperatures exceeding expected vehicle conditions, a key challenge to the use of HRE-free magnets. The Variant 1 motor also showed the best capability of meeting the US Drive technology 2020 targets, due to the high power-density of the permanent magnet motor and the potential cost reductions enabled by the removal of heavy rare earth materials. Variant 2 exhibited high efficiency in high speed regions due to the low high-speed losses, an important consideration for secondary traction applications, and significantly thrifted on magnet mass to reduce cost. Variant 3 contained copper bars within the induction rotor to reduce losses compared to cast aluminum, while using cast aluminum end-rings to reduce the cost and mass of the rotor. Optimization of the Cu-Al interface were focused on, as the interface is prone to forming brittle intermetallic compounds during the casting process. Prototypes of each motor variant were built and tested for performance, mechanical strength, and demagnetization resistance (Variants 1 and 2 only), with torque and power resulting close to the predicted values.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Flux Switching Permanent Magnet Motor with Metal Amorphous Nanocomposite Soft Magnetic Material and Rare Earth Free Permanent Magnets

The power losses in high power-density motors due to high rotational speed and/or high pole counts may be reduced adopting metal amorphous nanocomposites (MANCs) featuring low power loss and a relatively high flux density (~1.3 T). We recently proposed a flux switching permanent magnet (FSPM) motor with a rating of 2.5 kW at 1400 Hz electrical speed by incorporating low loss (< 3 W/kg at 1 kHz) FeNi-based MANC material with projected iron loss of about 5 W. The motor design allows use of rare earth-free permanent magnets. For incorporation of MANC materials, an axial flux motor where the rotor and stator core are made from a wound ribbon core has been developed. We have performed a 3-d FEA to optimize the design and built and tested a prototype demonstrating that the low loss MANC material can be used for motor applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2013

Phase transition and conduction mechanism in Pb{sub 2}Na{sub 0.8}R{sub 0.2}Nb{sub 4.8}Fe{sub 0.2}O{sub 15} material (R=rare earth)

Electrical properties of Pb{sub 2}Na{sub 0.8}Eu{sub 0.2}Nb{sub 4.8}Fe{sub 0.2}O{sub 15} tungsten bronze compound were investigated. Ferroelectric phase transition of diffuse type is observed at 395 °C. Conductivity study as a function of temperature (RT-600 °C) and at three different frequencies (10, 100 and 1000 kHz) suggests the existence of dominant ionic conduction. The rise of ac conductivity on increasing temperature supports the NTCR (negative temperature coefficient of resistance) behaviour of the material. The activation energies have been evaluated from ac conductivity using Arrhenius equation and discussed. Different conduction mechanisms were identified. For comparison, the conducting properties of Pb{sub 2}Na{sub 0.8}R{sub 0.2}Nb{sub 4.8}Fe{sub 0.2}O{sub 15} (R=Dy, Nd, La) were also investigated. - Graphical abstract: Thermal evolution of lnσ{sub ac} of Pb{sub 2}Na{sub 0.8}Eu{sub 0.2}Nb{sub 4.8}Fe{sub 0.2}O{sub 15} at selected frequencies. Display Omitted - Highlights: • We found that TB compounds exhibit a diffuse type of first- order transition. • A negative temperature coefficient of resistance (NTCR) behaviour is observed. • Three conduction mechanisms were identified: n-and/or p-type at low temperatures. • The conduction mechanism in the studied compounds is very complex.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗