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Laser powder bed fusion (L-PBF) was used to produce stator half-shells of a transverse flux machine from pure iron (99.9% Fe). In order to reduce iron losses in the bulk components, radially extending slits with a nominal width of 150 and 300 µm, respectively, were integrated during manufacturing. The components were subjected to a suitable heat treatment. In addition to a microscopic examination of the slit quality, the iron losses were also measured using both a commercial and a self-developed measurement setup. The investigations showed the iron losses can be reduced by up to 49% due to the integrated slits and the heat treatment.

In this work, two commercial indexable inserts with different coatings were examined with regard to their damage and wear characteristics after tool life testing on two different types of gray cast iron. The surface and chemical analysis by means of Scanning Electron Microscopy (SEM) and/or Energy Dispersive X-ray Spectroscopy (EDS) revealed a removal of the respective protective layer on the wear surface in varying degrees. In addition to that, crack structures were identified that take various forms as a function of the coating. The integrated Focused Ion Beam technology (FIB) also allowed to examine the identified cracks with regard to their propagation in the depth of the respective component. The cracks extend deep into the WC-Co base material and mainly propagate through the ductile Co phase.