Conceptual designs of 1.5 and 3.0 T full-body magnetic resonance imaging (MRI) magnets using conduction cooled MgB ₂ superconductor are presented. The sizes, locations, and number of turns in the eight coil bundles are determined using optimization methods that minimize the amount of superconducting wire and produce magnetic fields with an inhomogeneity of less than 10 ppm over a 45 cm diameter spherical volume. MgB ₂ superconducting wire is assessed in terms of the transport, thermal, and mechanical properties for these magnet designs. Careful calculations of the normal zone propagation velocity and minimum quench energies provide support for the necessity of active quench protection instead of passive protection for medium temperature superconductors such as MgB ₂ . A new ‘active’ protection scheme for medium T _c based MRI magnets is presented and simulations demonstrate that the magnet can be protected. Recent progress on persistent joints for multifilamentary MgB ₂ wire is presented. Finite difference calculations of the quench propagation and temperature rise during a quench conclude that active intervention is needed to reduce the temperature rise in the coil bundles and prevent damage to the superconductor. Comprehensive multiphysics and multiscale analytical and finite element analysis of the mechanical stress and strain in the MgB ₂ wire and epoxy for these designs are presented for the first time. From mechanical and thermal analysis of our designs we conclude there would be no damage to such a magnet during the manufacturing or operating stages, and that the magnet would survive various quench scenarios. This comprehensive set of magnet design considerations and analyses demonstrate the overall viability of 1.5 and 3.0 T MgB ₂ magnet designs.

Challenge 3 of the 2022 NIST additive manufacturing benchmark (AM Bench) experiments asked modelers to submit predictions for solid cooling rate, liquid cooling rate, time above melt, and melt pool geometry for single and multiple track laser powder bed fusion process using moving lasers. An in-house developed Additive Manufacturing Computational Fluid Dynamics code (AM-CFD) combined with a cylindrical heat source is implemented to accurately predict these experiments. Heuristic heat source calibration is proposed relating volumetric energy density (ψ) based on experiments available in the literature. The parameters of the heat source of the computational model are initially calibrated based on a Higher Order Proper Generalized Decomposition- (HOPGD) based surrogate model. The prediction using the calibrated heat source agrees quantitatively with NIST measurements for different process conditions (laser spot diameter, laser power, and scan speed). A scaling law based on keyhole formation is also utilized in calibrating the parameters of the cylindrical heat source and predicting the challenge experiments. In addition, an improvement on the heat source model is proposed to relate the Volumetric Energy Density (VED_σ) to the melt pool aspect ratio. The model shows further improvement in the prediction of the experimental measurements for the melt pool, including cases at higher VED_σ. Overall, it is concluded that the appropriate selection of laser heat source parameterization scheme along with the heat source model is crucial in the accurate prediction of melt pool geometry and thermal measurements while bypassing the expensive computational simulations that consider increased physics equations.