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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 OSTI2025

A rotor-based multileaf collimator for beam shaping

We introduce a new style of multileaf collimator which employs rotors with angularly dependent radius to control the masking aperture: a rotor-based multileaf collimator (RMLC). Using a padlock-inspired mechanism, a single motor can set dozens of rotors, i.e. leaves, independently. This is especially important for an ultra-high vacuum (UHV) compatible MLC, since this reduces the number of actuators and vacuum feedthroughs required by more than an order of magnitude. This new RMLC will complement previous work employing a UHV compatible MLC with an emittance exchange beamline to create arbitrarily shaped beams on demand. A feed-forward control system which abstracts away the complexity of the RMLC operation, and is adaptable to real beamline conditions, is discussed and demonstrated in simulation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Thermal Management Solution for an Integrated Outer-Rotor Motor Drive: Opportunities and Challenges

This work highlights an integrated thermal management solution for the outer-rotor motor (ORM) drive. The integrated ORM drive utilizes water-ethylene glycol coolant for power electronics and stator cooling. Air cooling is used for rotor laminations, magnets and outer-rotor structures, and the rotor shaft. To fully understand the performance of the integrated ORM drive and thermal management coupling effects, a full drive conjugate heat transfer model has been developed to investigate coupled cooling performance of various components of the ORM drive. Various motor rotational speeds, power output scenarios, and cooling options for the integrated ORM drive have been investigated. The model estimates the operating window for the ORM drive while keeping component operating temperatures below prescribed limits. The model also highlights the importance of windage losses at higher rotational speeds for this ORM design, which involves higher rotor surface area per unit width of the rotor. Different designs are also investigated, particularly focusing on rotor cooling with air either naturally induced by rotor spin or forced airflow with the help of a blower, to circumvent challenges imposed by higher windage losses. The work highlights motor rotational speed limitations and the need for potential liquid cooling options for desired rotor performance at higher rotational speeds. Liquid cooling for the rotor may even become more critical for nonuniform rotor-stator gaps, leading to even higher and uneven windage losses across the full circumference of the motor, consequentially, more heating for the rotor.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Investigation of a Multi-Rotor Triboelectric Nanogenerator Using a Modular Flexible Circuit Board Stack

Triboelectric nanogenerators (TENGs) are a nascent class of energy harvester that are being explored for scavenging energy from small ocean waves. To date, they have been integrated in wave energy converters (WECs) designed to capture random motion caused by the perturbations of the ocean surface. Blue economy applications such as ocean observation can benefit greatly from more substantial wave-derived power, as such, the power output of existing TENG WECs must be increased several-fold to become viable. This study describes the conceptualization of a rotary TENG, and the subsequent efforts to increase its power output by stacking multiple stator and rotor pairs. In the latter part of this study, we introduce a novel means of incorporating a friction element into the design of the TENG by employing flexible printed circuit board (PCB) rotors. At rest, these flexible rotors will contact the stator, building static charges due to friction, at speed, these flexible rotors will be decoupled from the stator, reducing friction and allowing faster rotation. Initial results indicate that the power output of the flexible PCB rotor does not produce more power than a rigid, acrylic disk rotor, however the current output of the prototype is boosted, and the prototype is far more compact, allowing for a higher energy density than the rigid rotor prototype.

bench testing↗
DOE OSTI2024

Development of Solid Synchronous Reluctance Rotors With Multi-Material Additive Manufacturing

Synchronous reluctance (SynR) machines are promising rare-earth material-free alternatives to permanent magnet machines. However, structural challenges limit their operating speed and power density. This paper proposes and investigates multi-material additive manufacturing (MMAM) as a key-enabler to realize power-dense and high-speed SynR machines. It does so by proposing designs that guide magnetic flux through solid rotors realized by selective placement of magnetic and non-magnetic materials. To explore this concept, first, material samples are additively manufactured and experimentally characterized to assess the structural and magnetic properties that can be expected for the proposed rotors. Second, the design space of each rotor type is explored using these measured properties within finite element analysis. The results reveal that MMAM can enable fabrication of SynR motors with power density levels that are at the leading edge of all conventional electric machine topologies. It is shown that tip speeds in excess of 300 m/s can be achieved, resulting in 3-4x improvement in power density over conventional SynR motors. A solid SynR rotor is printed in an experimental MMAM laser powder bed fusion system. The rotor is paired with an existing stator to create a functional SynR motor with a saliency ratio of 2.59 and torque rating of 4.15 Nm. This is the first publication of a SynR rotor prototype constructed via MMAM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Rotordynamic Analysis and Comparative Study of High-Speed Outer Rotor Permanent Magnet Motor Designs

High–power density electric motor designs are a requirement in aerospace and automotive applications. Outer rotor permanent magnet motors can offer high power density but have mechanical challenges such as structural stability and rotodynamic issues. In this work, a rotodynamic study was performed for two outer rotor permanent magnet motor designs. The first design was a cantilever design in which the rotor was suspended at one end, supported by four bearings; in the second design, the rotor was simply supported by two bearings in each end. Two different finite element method–based approaches, solid rotor and beam rotor methods, were used to extract the critical speed.

Barua, Himel↗
DOE OSTI2026

Multipoint Aerostructural Optimization of Wind Turbine Rotors Using a Coupled Blade‐Resolved Aerostructural Solver

Physics‐based design optimization workflows thread the needle between computational cost limitations and simulation complexity, often compromising between modeling detail and the range of operating design conditions. Multipoint aerostructural optimization of wind turbine rotors has so far been confined to low‐fidelity analyses or to high‐fidelity studies with simplified structural models, leaving the most complex design trade‐offs unexplored. We close this gap by performing the first tightly coupled gradient‐based multipoint aerostructural rotor optimization using 3D aerodynamic and structural solvers with discrete coupled adjoints. The optimizer simultaneously varies blade planform, airfoil shapes, and structural thickness through more than 270 design variables, minimizing a weighted combination of rotor mass and power across multiple wind speeds. Applied to a modified DTU 10‐MW benchmark under conservative structural and aerodynamic constraints, our multipoint optimization reduces rotor mass by up to 36% and increases power by 12%–15% across the main operating conditions; biasing the objective toward power yields power gains up to 18% and a 17% mass reduction. For a nominal wind distribution, 3‐point rotor designs accounting for low RPM and high thrust conditions capture dominant trade‐offs and outperform single‐point designs. Adding two off‐design points changes individual‐condition power by less than 3% but leaves the weighted average within 0.5%, and the mass‐power bias has a stronger effect on the final design than the operating‐point weighting itself. Our framework extends naturally to richer load cases and site‐specific wind distributions, providing a basis for high‐fidelity multipoint design earlier in industrial workflows.

17 WIND ENERGY↗
DOE OSTI2025

Characterization of HRRR-simulated rotor layer wind speeds and clouds along the coast of California

Stratocumulus clouds, with their low cloud base and top, affect the atmospheric boundary layer wind and turbulence profile, thereby modulating wind energy resources. GOES satellite data reveal an abundance of stratocumulus clouds in the late spring and summer months off the coast of northern and central California, where there are active plans to deploy floating offshore wind farms at two lease areas (near Morro Bay and Humboldt). Since the fall of 2020, two buoys equipped with multiple instruments, including Doppler lidar, have been deployed for about 1 year in these wind farm lease areas to assess the rotor layer wind conditions in these locations. The objective of this study is to evaluate how well the High-Resolution Rapid Refresh (HRRR) model represents stratocumulus cloud characteristics and turbine-relevant rotor layer winds (surface to 300 m) by comparing HRRR simulations with buoy and satellite observations. We first find that the HRRR model reproduces the seasonal cycle of cloud top height reasonably well in these regions. However, during the warm season – especially at Morro Bay – the HRRR-simulated stratocumulus clouds tend to have lower tops by about 150 m and exhibit weaker diurnal cycles than satellite observations. Our analysis also shows that rotor layer wind speeds and vertical shear are stronger at Humboldt than at Morro Bay, and both are generally stronger under clear-sky conditions. Finally, the HRRR model bias in rotor layer wind speed is small under cloudy conditions but larger and dependent on observed wind speed under clear skies. Specifically, HRRR underestimates wind speeds at Morro Bay and overestimates them at Humboldt under clear-sky conditions.

17 WIND ENERGY↗
DOE OSTI2024

50 MW Segmented Ultralight Morphing Rotors for Wind Energy

A multi-institutional team designed a 50 Megawatt (MW) rated wind turbine featuring downwind aeroelastic morphing to reduce blade loads and allow an ultralight segmented rotor (mass reduction of about 25% compared to a conventional upwind rotor). The team used a control co-design approach with state-of-the art simulations including for the rotor and tower design using non-linear fluid-structure interactions and control algorithms, and the team also designed, built, and field-tested an aeroelastically-scaled downwind rotor to demonstrate this novel technology and validate the design tool fidelity. In a follow-on phase, these results were used along with an updated Levelized Cost Of Energy (LCOE) methodology to co-design a more detailed set of 25 MW rated turbine designs (including individual pitch control) based on minimum LCOE with highly flexible blades for an Atlantic Ocean offshore fixed-bottom design targeted towards market technology evaluation. A set of upwind and downwind designs at 25 MW rated scales were found to provide the best LCOE, with strong improvements over all previous offshore reference turbines (NREL 5MW, DTU 10 MW and IEA 15 MW). The optimized design would represent the world’s largest offshore turbine design, which combines several state-of-the-art structural, aerodynamic, and control technologies into a new and optimized system concept.

17 WIND ENERGY↗
DOE OSTI2024

Study of a High-speed Outer Rotor Burst Containing Enclosure

The increasing demand for high-speed electric machines in many applications pushes the development of high-power density electric motors. Outer rotor motors, which can be designed with a larger airgap diameter than inner rotor motors for the same overall diameter and, therefore, provide higher torque, distinguish themselves in space-constrained but high torque applications. However, increasing the motor speed and diameter results in significant centrifugal loads for the outer rotor motor due to its higher airgap diameter. Additional attention must be paid at the design stage to consider the extreme situation of possible mechanical failure, such as the sudden burst of the high-speed rotating parts in the motor, and measures must be taken to prevent their damage to other system components in advance. Through the finite element dynamic impact analysis, we studied the damage caused by broken parts on the inner wall of the electric motor housing when the motor rotates at 20,000 RPM. The proposed method is expected to provide reasonable recommendations of the enclosure material and its thickness required to protect other components in the same powertrain system when the high-power density motor fails unexpectedly.

Lin, Lianshan↗
DOE OSTI2024

Crack Propagation Modeling of a High-Speed Outer Rotor Motor

This study aims to investigate the propagation of initial cracks in electric motors and their rate of spread through the rotor structure under various operating conditions. Traction motors are subjected to high centrifugal load owing to their speed and rapid acceleration and deceleration. In the manufacturing process, some initial imperfections or cracks in the rotor components are likely to occur. Under the influence of loading, these cracks will grow, and factors such as loading frequency, material strength, and location of material voids will affect this threshold speed. In the current study, a fracture mechanics–based approach has been used to investigate the crack growth rate for a 100 kW outer rotor motor with a rated speed of 6,000 rpm and a peak speed of 20,000 rpm for an integrated drive application.

Barua, Himel↗
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 OSTI2024

Challenges in Rotor Aerodynamic Modeling for Non-Uniform Inflow Conditions

Within an international collaboration framework, the accuracy of rotor aerodynamic models used for design load calculations of wind turbines is being assessed. Where the use of high-fidelity computation fluid dynamics (CFD) and mid-fidelity free-vortex wake (FVW) models has become commonplace within the wind energy community, these still fail to meet the requirements in terms of execution time and computational cost needed for design load calculations. The fast but engineering fidelity blade-element/momentum (BEM) method can therefore still be considered the industry workhorse for design load simulations. At the same time, upscaling of wind turbine rotors makes inflow non-uniformities (e.g. shear, veer, turbulence) more important. The objective of this work is to assess model accuracy in non-uniform inflow conditions, which violate several BEM assumptions. Thereto a comparison in turbulent inflow has been executed including a wide variety of codes, focusing on the DanAero field measurements, where a 2.3-MW turbine was equipped with, among other sensors, a pressure measurement apparatus. The results indicate that, although average load patterns are in good agreement, this does not hold for the unsteady loads that drive fatigue damage and aero-elastic stability. A simplified comparison round in vertical shear was initiated to investigate the observed differences in a more controlled manner. A consistent offset in load amplitude was observed between CFD and free-vortex codes on the one hand and BEM-type codes on the other hand. To shed more light on the observations, dedicated efforts are ongoing to pinpoint the cause for these differences, in the end leading to guidelines for an improved BEM implementation.

17 WIND ENERGY↗
DOE OSTI2026

Experimental Results for an Inverter Integrated with A High-Speed Surface Permanent Magnet External Rotor Motor

This work presents the prototyping and testing of a high-speed outer rotor surface permanent magnet motor. The motor employs non-heavy rare-earth permanent magnets and operates at a rated speed of 6,666 rpm. In-slot ceramic heat exchangers are used to cool the windings. The external rotor configuration provides substantial space within the stator bore, which is used for power electronics integration. This integration introduces several design and thermal management challenges that are discussed in the paper. The machine has been prototyped and tested under various operating conditions, and both simulation and experimental results are presented.

Rallabandi, Vandana [ORNL] (ORCID:0000000236241901↗
DOE OSTI2025

Deployment of Digital Twins and Advanced Instrumentation to Identify Looseness Between Rotor Spider Arms and Rim Attachment in Hydro Turbines

The project aimed to develop a Virtual Sensor Digital Twin (VS-DT) to monitor rotor rim float displacement (RRFD) in legacy hydropower turbines. RRFD, if undetected, can cause rotor and stator damage, leading to costly repairs and safety concerns. The purpose of the VS-DT was to predict RRFD signals using existing conventional sensors instead of installing dedicated, costly physical sensors, thereby reducing operational costs and enhancing safety.

13 HYDRO ENERGY↗
DOE OSTI2025

Wind Turbine Rotor Design Using High-Fidelity Aerostructural Optimization

Large wind turbines yield more energy but demand careful aeroelastic blade design. Coupled multiphysics design strategies can reduce wind energy costs by exploiting fluid-structure interactions. This work presents the first high-fidelity aerostructural optimization study of a large wind turbine rotor. We use blade-resolved fluid dynamics and structural solvers in a monolithic gradient-based optimization framework to explore steady-state torque and blade mass tradeoffs. The coupled-adjoint approach computes gradients efficiently, enabling the optimization of over 100 structural and geometric parameters simultaneously. Our optimization study modifies a DTU 10 MW benchmark with a simplified structure and isotropic material properties. The tightly coupled optimizations increase torque by 14% while reducing rotor mass by 9% or reduce blade mass by 27% while maintaining torque. Blade-resolved models provide greater design freedom, enabling 5% higher mass reductions than conventional parameterizations at equal torque. This framework paves the way for more detailed high-fidelity optimization studies to complement conventional design approaches.

17 WIND ENERGY↗
DOE OSTI2025

Additively manufactured and cast high-temperature aluminum alloys for electric vehicle brake rotor application

Electric vehicle brake rotors demand lightweight, high thermal conductivity materials with good resistance to wear, creep, salt corrosion, and thermal fade, all of which present challenges to the traditionally used cast iron. In this work, we investigated the braking performance of recently developed high-temperature aluminum alloys in both cast and 3D printed forms, that possess excellent microstructural and mechanical stability at elevated temperatures. Three aluminum alloys, Al-6Cu-Mn-Zr, Al-9Cu-Mn-Zr, and Al-Ce-Ni-Mn-Zr and a reference cast iron were tested on a sub-scale brake tester against a commercial brake pad material over a range of sliding speeds between 2 and 15 m/s. The performance of these alloys was evaluated for wear resistance, friction behavior, temperature elevation, and surface morphological change. Although all three candidate alloys had lower wear-resistance than cast iron, Al-Ce-Ni-Mn-Zr showed a significantly reduced wear rate in comparison to the Al-Cu-Mn-Zr alloys. Moreover, Al-Ce-Ni-Mn-Zr alloy had the most consistent friction behavior at all sliding speeds and good fade resistance, as the coefficient of friction did not dramatically decrease with temperature rise but stayed within a desirable range of 0.35–0.50 instead. The superior wear resistance and braking performance of the Al-Ce-Ni-Mn-Zr alloy were attributed to its higher hardness, and high temperature yield strength and creep resistance compared with the Al-Cu-Mn-Zr alloys. In conclusion, the results suggest that the braking performance of these aluminum alloys could be further enhanced by increasing the hardness and forming a more stable transfer layer on the sliding surface.

36 MATERIALS SCIENCE↗