Additive Manufacturing of High Performance Ferromagnetic Materials

Pham, Thang Q.; Do, T. Truong; Kwon, Patrick; Foster, Shanelle N.

doi:10.1109/ecce.2018.8558245

Cited by 22 publications

(7 citation statements)

References 29 publications

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“…Electrical resistivity of a particular conductor material is a measure of how strongly the material opposes the flow of electric current through it. Electrical resistivity (ρ) is proportional to the resistance (R), the cross-sectional area (A) and the length (l) of the object, as expressed in (1).…”

Section: Methodsmentioning

confidence: 99%

“…Previously, different machines with powder metallurgy cores have been shown to benefit from three-dimensional flux paths: such as claw pole or pancake motors or designs involved in transverse flux. [1] These designs can also be realized with AM, additionally with more refined geometries. The main advantage of 3D printing lies in its capacity for realizing finite walls (up to 60 μm) and achieving partially hollow structures: improving motor cooling capacity, moment of inertia and material efficiency [2].…”

Section: Introductionmentioning

confidence: 99%

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Electrical Resistivity of Additively Manufactured Silicon Steel for Electrical Machine Fabrication

Tiismus

Kallaste

Vaimann

et al. 2019

2019 Electric Power Quality and Supply Reliability Conference (PQ) &Amp; 2019 Symposium on Electrical Engineering and Mechatron

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Additive manufacturing, commonly labeled as 3D printing is an essential component of the next industrial revolution, enabling both unprecedented fabrication freedom and streamlined production and logistics. Traditionally, the electrical machine cores are stacked from varnished soft magnetic laminations, which deliver reduced eddy and hysteresis losses during machine operation. Presently, dedicated metal printing platforms can produce industrial grade homomaterial metal components, promoting the fabrication of machines with highly complex topologies, but also increasing the eddy current induced in these components, due to lack of laminated structure. In this paper, we present experimental resistivity measurement results of 3% and 6.5% silicon content steel fabricated with selective laser melting.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Electrical Resistivity of Additively Manufactured Silicon Steel for Electrical Machine Fabrication

Tiismus

Kallaste

Vaimann

et al. 2019

2019 Electric Power Quality and Supply Reliability Conference (PQ) &Amp; 2019 Symposium on Electrical Engineering and Mechatron

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“…Binder jet printing (BJP) is another AM technique that does not use laser as an energy source. In [40], the BJP process is used to prepare iron-silicon samples with superior relative permeability in comparison to commercial soft magnetic composites (SMCs). Maximum relative permeability of BJP iron-silicon can be improved to more than 10,000 under postprocessing heat treatment [41].…”

Section: Iron-silicon (Fesi)mentioning

confidence: 99%

“…Table 1. Comparison of grain size and maximum relative permeability between as-built and heattreated printed soft magnetic materials [34,37,40,43,45].…”

Section: Performance Of Additively Manufactured Soft Magnetic Materialsmentioning

confidence: 99%

Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review

2021

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Additive manufacturing has many advantages over traditional manufacturing methods and has been increasingly used in medical, aerospace, and automotive applications. The flexibility of additive manufacturing technologies to fabricate complex geometries from copper, polymer, and ferrous materials presents unique opportunities for new design concepts and improved machine power density without significantly increasing production and prototyping cost. Topology optimization investigates the optimal distribution of single or multiple materials within a defined design space, and can lead to unique geometries not realizable with conventional optimization techniques. As an enabling technology, additive manufacturing provides an opportunity for machine designers to overcome the current manufacturing limitation that inhibit adoption of topology optimization. Successful integration of additive manufacturing and topology optimization for fabricating magnetic components for electrical machines can enable new tools for electrical machine designers. This article presents a comprehensive review of the latest achievements in the application of additive manufacturing, topology optimization, and their integration for electrical machines and their magnetic components.

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“…Presently, full 3D printing of EM is yet to be achieved, however all the necessary components have successfully been individually fabricated: soft magnetic rotor [1], [2] and stator designs [3], gapped [4] and insulated [5] coils and metal bearings [6]. Majority of the printed soft ferromagnetic components have been fabricated with Selective Laser Melting (SLM) systems in the literature, with the exception of [7] binder jetting (BJ) and [8] Laser Engineered Net Shaping (LENS) technologies. In the case of printed electromechanical devices, the magnetic flux guides are expected to exhibit high saturation magnetization for amplifying the magnetic interactions in the machine air gap and low coercivity, i.e.…”

Section: Introductionmentioning

confidence: 99%