The chance to move from 2D to 3D approach in the design of the electrical machines is made possible by the availability of Soft Magnetic Composites (SMC), iron based powders, insulated and pressed to realize shapes otherwise impossible with the traditional lamination sheets technology. Some commercial products are available on the market as “ready to press” powders, which presents good magnetic and energetic properties but are sometimes weak under the mechanical point of view; other products aim at improving this aspect but with considerable process complications and relative cost. The experience of the Authors in the realization of bonded magnets with the adoption of selected organic resins has been partly transferred in the research field of the SMC in order to investigate the possibility to obtain good mechanical properties maintaining the magnetic characteristics of the Insulated Iron Powder Compounds (I.I.P.C.) taken as reference. The paper presents the activity that has been carried out in the realization of SMC mixing iron powders and phenolic resin, in different weight percentages and mold pressures. The obtained results are considered satisfactory under the point of view of the compromise between magnetic and mechanical properties, considering also that the required productive process is simpler. The comparison of the obtained results with those related to commercial products encourages to carry on the research, also because of the reduced cost of the proposed SMC at parity (or better) performance.

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The interest around the adoption of Soft Magnetic Composite materials (SMC) in the realization of electric machines, or parts of electric machines, is continuously increasing. The main reason lies on the opportunity to realize magnetic circuits following a 3D design procedure, which is not allowed with the adoption of the traditional lamination sheets. This is not the only reason, as a lot of research is being carried out on the losses distribution in the magnetic material, particularly as function of the frequency. In this paper different iron powders have been analyzed to investigate the impact of the granulometry on the SMC performance; in particular the grain size and the oxygen content have been considered variable parameters. The materials, prepared, compacted and tested in our laboratories, have been characterized to obtain the magnetic characteristic and information about the iron losses.

In electrical machines, laminated steels are commonly adopted as soft magnetic materials, while for permanent magnets, sintered ferrites and NdFeB are the most common solutions. On the other hand, the growing demand for volume reduction with the increment of efficiency leads to the necessity of exploring other magnetic materials able to face the challenge better than the traditional ones. Bonded magnets have been used to replace sintered magnets, obtaining a better use of space and particular magnetic properties. Instead, for the magnetic circuit, Soft Magnetic Composites (SMC) allow realizing very complex magnetic design (3D path for flux) with iron loss reduction at medium-high frequencies, especially for the eddy currents loss contribution. On the other hand, SMC materials have such drawbacks as low mechanical properties and high hysteresis losses. For this reason, in this work, different studies considering several variables have been carried out. SMCs were produced through a moulding process; inorganic and organic layers to cover ferromagnetic particles were used, adopting different coating processes. Particular tests have been performed for a quicker and more indicative overview of the materials obtained. The single sheet tester (SST) is easier than traditional toroidal methods; on the other hand, the multiplicity of variables affects the SMC materials and their process. For this reason, coercivity and conductibility tests permit rapid measurement and provide a direct classification of the produced SMCs, providing the main information needed to select suitable materials. Results highlighted that choosing the more appropriate SMC material is possible after using these simple preliminary tests. After these tests, it was possible to argue that with 0.2 wt% of phenolic resin as the organic layer (and compaction pressure of 800 MPa), it is possible to produce a good SMC. On the other hand, the SMC with 0.2 wt% of epoxy resin (and compaction pressure of 800 MPa) gives a minor coercivity value. Additionally, despite the SMC with the inorganic layer, 0.2 wt% of nano-ferrites showing the best coercivity values (specifically for vacuum treatment at 600 °C), their resistivity was unsatisfactory.