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DOE OSTI2025

Sensitivity of magnetic islands in permanent magnet stellarators using the gradient and Hessian methods

Stellarator plasmas are known to be very sensitive to perturbations in the magnetic field. The permanent magnet stellarator was in part developed as a solution to high machining tolerances placed on the shape properties of electromagnetic coils in traditional stellarators. However, as a consequence of this high sensitivity to the field structure, sensitivities of permanent magnet stellarator plasmas to perturbations of permanent magnet properties must necessarily be well-understood. The gradient and Hessian matrix methods have been previously demonstrated to be useful sensitivity analysis methods for modular coils. We apply these two methods to the study of island width sensitivities in both the MUSE and PM4STELL permanent magnet stellarator projects. These sensitivity methods were used to determine the relative impacts of permanent magnet parameter perturbations on island widths in the vacuum field approximation of both stellarator equilibria. The square of resonant magnetic field perturbation is used here as a proxy for island width. In particular, gradients of magnetizations of individual magnets were examined in MUSE, as well as gradients of magnet group displacements informed by device design. Three different forms of permanent magnet magnetization perturbations are investigated for MUSE, and the flux surface response to perturbations is demonstrated. The Hessian matrix method is applied to PM4STELL, illustrating the sensitivity of dominant island widths to displacements of toroidal wedge structures. These methods allow for selective direction of experimental resources toward regions of heightened sensitivity, while constraints on less impactful permanent magnet parameters can be relaxed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Focusing of relativistic electron beams with permanent magnetic solenoid

Achieving strong focusing of MeV electron beams is a critical requirement for advanced beam applications such as compact laboratory x-ray sources, high gradient accelerators, and ultrafast electron scattering instrumentation. To address these needs, a compact radially magnetized permanent magnetic solenoid (PMS) has been designed, fabricated, and tested. The solenoid provides a compact and inexpensive solution for delivering high axial magnetic fields (1 T) to focus MeV electron beams. Field characterization of the solenoid demonstrates good agreement with analytical models, validating the PMS design. The electron beam test employs a high-brightness photoinjector to study the focusing properties of the PMS. The results indicate a focal length of less than 10 cm and a significant reduction in beam size with small spherical aberrations. Two application cases are evaluated: angular magnification in ultrafast electron diffraction setups and strong focusing for Compton scattering or other microfocus uses.

Electron diffraction↗

DOE OSTI2026

Status of permanent magnet radiation resiliency studies at CEBAF

An ongoing investigation for the future of Jefferson Lab’s Continuous Electron Beam Accelerator Facility (CEBAF) lies in upgrading its maximum nominal energy using Fixed-Field Alternating-gradient (FFA) technology for its recirculating arcs, using permanent magnets for the FFA arcs. A common concern among the community is the degradation of these permanent magnets during operation due to the radiation environment in which they will be present. This work, funded by a Laboratory Directed R&D grant, aims to measure the permanent magnet degradation in the CEBAF tunnel enclosure, and extrapolate to the energies expected from the upgrade. We present the latest results of this study, as well as plans moving forward.

Accelerator Physics↗

DOE OSTI2025

Universal Electronic‐Structure Relationship Governing Intrinsic Magnetic Properties in Permanent Magnets

An electronic-structure-centered perspective is presented on permanent-magnet (PM) design, highlighting two key levers, that is, saturation magnetization (M s ), governed by 3d-band filling and exchange physics, and magnetocrystalline anisotropy energy (MAE), arising from spin-orbit coupling (SOC) on anisotropic orbital populations. Reviewing current practices, including DFT-based MAE/J ij extraction, atomistic-spin and micromagnetic modeling, and high-throughput machine learning (ML) pipelines, three bottlenecks limiting predictive discovery is identified that is i) electronic-structure accuracy for small MAE (sensitive to functional choice, Hubbard U, and many-body effects), ii) finite-temperature and kinetic realism (phonon/magnon renormalization, ordering kinetics), and iii) descriptor and multiscale decoupling (lack of SOC-weighted and orbital-resolved fingerprints). Deep dives into the electronic-structure of Nd─Fe─B and Fe─N show how these fingerprints govern magnetic performance, motivating DFT- and quantum-mechanics-based descriptors for discovery. Unbiased, structure-driven exploration, coupled with high-throughput simulations, ML, generative AI, and reasoning models, accelerates candidate identification and propagates insights across scales. Addressing supply-chain risks, on future needs of designing “critical-element-free” magnets with tailored microstructure and high energy products is emphasized. By integrating electronic fingerprints, AI reasoning, and multiscale modeling, a practical roadmap is provided for rare-earth-lean or rare-earth free, high-performance, sustainable PMs.

Singh, Prashant [Ames Laboratory, and Iowa State U↗

DOE OSTI2026

A solid-state extrusion pathway extensible to upcycling aluminum scrap and end-of-life permanent magnets into ductile Al-6061/SmCo 5 structural magnetic composites

Permanent magnets offer strong potential for multifunctional structural components, but their inherent brittleness limits direct integration. Here, SolidStir® Extrusion (SSE) is used to embed SmCo5 powder into AA6061 in the solid state, and the resulting microstructure, interfacial chemistry, mechanical properties, and magnetic response are systematically characterized. SSE fragments the initial SmCo 5 powder into predominantly fine particles dispersed within an ultrafine Al matrix, with a volume fraction of ∼ 4–6 % in this proof-of-concept study. Interfacial reactions form a continuous Al–Co reaction layer, with local atomic-resolution indexing consistent with Al 13 Co 4 , together with Sm–Si-rich reaction products, while the matrix contains Sm–Co–Si-rich precipitates and Mg 2 Si, producing features from nanometers to micrometers. Compared with an Al extrudate, this architecture increases yield strength by ∼ 42 % and tensile strength by ∼ 31 %, while preserving uniform elongation, and it sustains work hardening in compression from 150 to 400 °C. The composite retained hard-magnetic behavior, with axial magnetization of 12.7 A·m 2 kg −1 at 6 T and intrinsic coercivity of 9.6 kOe. These findings demonstrate that SSE can produce Al-based load-bearing magnetic composites while preserving useful SmCo5 functionality.

36 MATERIALS SCIENCE↗

DOE OSTI2025

MnBi 2 Is a Permanent Magnet

Creating and understanding new permanent magnets requires an understanding of the impact of orbital angular momentum on coercivity. A simple approach to interrogating this relationship is by incorporating high Z (where Z is the atomic number) elements into binary compounds to maximize spin–orbit coupling. The Mn–Bi system is an appealing platform for these studies since it contains MnBi, a permanent magnet with a large coercive field. We previously identified a new compound in the Mn–Bi system, MnBi 2 , but could not elucidate its magnetic properties ex situ due to its decomposition upon decompression. Here, we harnessed synchrotron X-ray magnetic circular dichroism to probe the magnetism of MnBi 2 at high pressure within a diamond anvil cell. Our results indicate that MnBi 2 exhibits ferromagnetic hysteresis at both 10 K and room temperature. Through calculations and experiments, we show that orbital angular momentum and spin–orbit coupling from Bi impart magnetic anisotropy in MnBi 2 . Comparing the Mn–Bi family of compounds, we consider the Bi p and d orbitals to explain the differences in magnetic behavior within the system. Collectively, these results validate leveraging high-Z elements in the synthesis of new hard permanent magnets.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Permanent magnets for ELM suppression in tokamaks: feasibility and operational compatibility

Permanent magnets can provide static magnetic fields without power supplies or feed lines, offering a simpler alternative to conventional electromagnets in tokamaks. This work examines permanent magnet arrays (PMAs) for edge localized mode (ELM) control in double-null (DN) configurations, where traditional RMP coils exhibit limited effectiveness. Linear plasma response calculations using IPEC assess high-field-side (HFS) permanent magnet placement, benchmarking performance against DIII-D low-field-side (LFS) internal coils (I-coils) while evaluating engineering constraints. Modeling results demonstrate that HFS permanent magnet configurations generate HFS plasma response amplitudes more than 5 times larger than conventional I-coil systems. While other resonant response metrics show comparable or reduced response relative to I-coils, the combination of conventional RMP systems and permanent magnets is expected to provide enhanced performance. Operational impact assessments of persistent magnetic fields, including sideband field effects and startup/ramp-up compatibility, reveal acceptable performance within established operational boundaries. This analysis establishes PMAs as a technically viable approach for DN ELM control with reductions in system complexity, motivating further experimental validation on existing tokamak facilities.

3D magnetic perturbation↗

DOE OSTI2025

High-performance permanent-magnet materials based on CeFe 12

We perform first-principles calculations on the Mo/Zr-alloyed ThMn 12 -structure prototype CeFe 12 to explore its electronic and magnetic properties and potential for permanent magnet applications. A recent experiment has shown that the Mo/Zr-alloyed CeFe 12 phase with the symmetry 𝐼⁢4/𝑚⁢𝑚⁢𝑚 can be stabilized in bulk. It encourages an investigation into the intrinsic magnetic characteristics of the base structure CeFe 12 and the effect of transition metal alloying in it. Our calculations reveal that the base structure prototype CeFe 12 in its tetragonal phase exhibits uniaxial magnetic anisotropy with a magnetic anisotropy energy (𝐾 1 ) ∼ 1 MJ/m −3 and a substantial magnetic moment of ∼ 1.8T, showing its promise as a permanent magnet. The introduction of the stabilizing transition metals Zr, Mo, and W reduces these values but still keeps the materials very promising. Notably, when 50% of Ce is substituted by Sm in Mo-alloyed CeFe 12 , the 𝐾 1 is significantly enhanced, accompanied by a fairly decent magnetic moment of ∼ 1.2T. These findings establish this alloy as a strong candidate for high-performance permanent magnet applications. In conclusion, this study emphasizes the importance of strategic element substitution and site selection in transition metal-alloyed CeFe 12 to achieve both structural stability and remarkable magnetic properties.

Density of states↗

DOE OSTI2025

Synthesis and properties of bulk cobalt-carbide permanent magnets

Nanocrystalline bulk Co-C permanent magnets were produced by rapid hot consolidation of ball milled powder precursors. Bulk magnets with an average grain size of 20 nm and densities up to 94 percent of the theoretical density were successfully processed at pressures exceeding 1 GPa for the first time. Their microstructural and magnetic properties along with their magnetocrystalline anisotropy values are reported. Presence of iron contamination that results from the use steel milling media in milling was confirmed by elemental mapping of the bulk magnets. It is concluded that iron bonds in the form of hematite and does not adversely affect coercivity values. Here, this study shows that the Co 3 C compound does possess a sizable magnetocrystalline anisotropy, making it a suitable candidate as a rare earth free permanent magnet.

Co3 C↗

DOE OSTI2025

Error field measurements and correction on MUSE permanent magnet stellarator

The magnetic field topology and error fields are measured in the MUSE permanent magnet stellarator with an electron beam and fluorescent rod. The effective magnetization of the magnets is determined by measuring rational flux surface locations. Electron magnetic drift effects must be considered self-consistently due to the small magnetic shear on MUSE. Error fields are characterized by flux surface shape deviation and magnetic island chain width and phase. Error fields are then corrected by adjusting the permanent magnet (PM) holders as rigid bodies. Resonant error fields are on the order of or smaller than 3 x 10 -6 of the toroidal field after correction and surface shape matches well with the design. Resonant components of the quasi-symmetry deviation are estimated, using a novel magnetic drift measurement, to be in the 10 −4 range. The PM approach is validated as a low-cost and precise way to build optimized stellarators.

electron beam mapping↗

DOE OSTI2026

Status Update of Permanent Magnet Radiation Resiliency Studies at CEBAF

The proposed energy upgrade of the Continuous Electron Beam Accelerator Facility (CEBAF) incorporates Fixed-Field Alternating-gradient (FFA) arcs utilizing permanent magnet technology. Given the radiation environment within the CEBAF tunnel enclosure, validating the long-term magnetic stability of these materials is a critical step for the project's technical feasibility. This contribution presents an overview of the ongoing permanent magnet radiation resiliency program at Jefferson Lab. We briefly review the experimental methodology used to monitor demagnetization in situ and summarize the operational experience from the initial data-taking campaign. Furthermore, we discuss the upgrades implemented for the second exposure campaign, currently underway, which aims to refine dose correlation and reduce systematic uncertainties. We report on the general status of the program and the roadmap for certifying permanent magnet optics for the proposed upgrade energies.

Bodenstein, R. [Thomas Jefferson National Accelera↗

DOE OSTI2026

Thermal Management for a Novel Non-Heavy Rare-Earth Interior Permanent Magnet Machine

The work presents a thermal management solution for a novel non-heavy rare-earth permanent magnet machine being developed at Oak Ridge National Laboratory. The motor has been designed to minimize losses while maximizing performance for a range of speeds and power ratings. The novel motor design reduces rare-earth magnet usage, thereby avoiding supply chain issues. The motor component heat losses are established for operating windows and desired performance. These heat losses, along with windage losses, are being used to develop cooling solutions for different components of this machine. A novel thermal management solution for stators and rotors has been developed, and progress is presented in this paper. The stator cooling is achieved with the help of water-ethylene glycol flowing over the finned aluminum stator jacket, and rotor cooling with automatic transmission fluid passing through novel channels designed in the rotor laminations. The attempt is to establish effective cooling of the stator winding, laminations, and rotor magnets. A 3D conjugate heat transfer model has been developed for overall thermal analysis to establish a down- selected thermal management solution for the machine. The model, in addition to estimated component heat losses, includes windage losses and its impact on rotor and stator cooling. Overall, the work presents a workable thermal solution for the interior permanent magnet machine with potential for further improvements. Future work will involve establishing end winding and refinement of other end parts of the machine with the aim of establishing a robust thermal management solution. The work will also focus on different shapes (e.g., round, non-round, presence of wedges) of rotor-stator gaps and investigate windage losses and their impact on thermal management for higher rotational speeds for the machine.

30 DIRECT ENERGY CONVERSION↗

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

Current status of permanent magnet radiation resiliency studies at CEBAF

One possible future for Jefferson Lab’s Continuous Electron Beam Accelerator Facility (CEBAF) lies in upgrading its maximum nominal energy using Fixed-Field Alternating-gradient (FFA) technology for its recirculating arcs. The current proposal aims to use permanent magnets to supply the fixed fields. One concern among reviewers is the degradation of these permanent magnets during operation due to the radiation environment in which they will be present. This work, funded by a Laboratory Directed R&D grant, aims to measure the magnet degradation in the CEBAF tunnel enclosure, and extrapolate to the energies expected from the upgrade. We present the latest results of this study, as well as plans moving forward.

Accelerator Physics↗

DOE OSTI2026

Final design and first use of in-situ measuring apparatus for measurement of permanent magnet resiliency in CEBAF’s radiation environment

In this work we outline the final design and initial measurement lessons for the holders and measuring apparatus of the permanent magnet resiliency experiment which is a part of the FFA@CEBAF proposed upgrade. The experiment will expose permanent magnets to the radiation environment of CEBAF. Due to safety regulations we need to measure the magnets in the tunnel without bringing them out, so we designed a mobile measuring system as well as a series of protocols to allow us to speedily measure these samples even under adverse conditions. We also designed our system to be capable of taking measurements even with component failures.

Accelerator Physics↗

DOE OSTI2025

Modeling and design of compact, permanent-magnet transport systems for highly divergent, broad energy spread laser-driven proton beams

Laser-driven (LD) ion acceleration has been explored in a newly constructed short focal length laser beamline at the BELLA petawatt facility (interaction point 2, iP2). For applications utilizing such LD ion beams, a beam transport system is required, which for reasons of compactness be ideally contained within 3 m. While they are generated from a micron-scale source, large divergence and energy spread of LD ion beams present a unique challenge to transporting them compared to beams from conventional accelerators. This study gives an overview of proposed compact transport designs using permanent magnets satisfying different requirements depending on the application for the iP2 laser beamline such as radiation biology, material science, and high-energy density science. These designs are optimized for different parameters such as energy spread and peak proton density according to the application’s need. The various designs consist solely of permanent magnet elements, which can provide high magnetic field gradients on a small footprint. While the field strengths are fixed, we have shown that the beam size is able to be tuned effectively by varying the placement of the magnets. The performance of each design was evaluated based on high-order particle tracking simulations of typical LD proton beams. We also examine the ability of certain configurations to tune and select beam energies, critical for specific applications. A more detailed investigation was carried out for a design to deliver 10 MeV LD accelerated ions for radiation biology applications. With these transport system designs, the iP2 laser beamline is ready to house various application experiments.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Demagnetization analysis of an 18 GHz electron cyclotron resonance ion source permanent magnet hexapole

An upgrade of ECR2 at the Argonne Tandem Linac Accelerator System is under way, focusing on increasing the intensity capabilities of the facility. ECR2 is a room temperature electron cyclotron resonance ion source, and the upgrade has strict requirements to retain radial access to the plasma chamber and keep the ion source operating without the use of superconducting magnets. The upgrade design with respect to the magnet arrangement and magnetization vectors has recently been presented [R. C. Vondrasek, J. McLain, and R. H. Scott, J. Phys.: Conf. Ser. 2743 , 012044 (2024)] using the same magnetic material as the current ECR2 hexapole. A thorough exploration of the demagnetization potential of this hexapole was carried out, and the risk of demagnetization was deemed too high, despite the magnetic performance meeting the requirements for the upgrade. Additional permanent magnet materials are considered with their respective performance evaluated. Magnet strength and demagnetization resistance are investigated and optimized with the final room temperature design demonstrating a high temperature transient demagnetization resistance and a radial magnetic field of 1.18 T at the plasma chamber wall. Finally, the simulations of this hexapole suggest that it will be sufficient to optimize intensity with a 14.5 GHz driving frequency and will allow 18 GHz operation, while keeping a high safety margin for maintaining magnet performance.

Argonne Tandem Linac Accelerator System↗

DOE OSTI2025

Jump-Start U.S. Manufacturing of High-Performance Permanent Magnets

Gas atomized feedstock powders for Nd-Fe-B based magnets are more robust and cost effective than the strip-cast sheet currently used as feedstock for milling by the magnet industry. However, gas atomized powder’s crystallinity and grain boundary phases are less ideal than the strip cast flake. We proposed to optimize the atomization process as well as the powder chemistry to address this issue and to eliminate heavy rare earth elements from these magnet alloys. Our goal is to help GKN-Hoeganaes, a US metal powder company, who used to make Nd-Fe-B magnets, to bring back US manufacturing of these high energy density permanent magnets.

36 MATERIALS SCIENCE↗