Additive manufacturing of soft magnets for electrical machines—a review

Lamichhane, Tej N.; Sethuraman, Latha; Dalagan, Adrian; Wang, Haobo; Keller, Jonathan; Paranthaman, M.

doi:10.1016/j.mtphys.2020.100255

Cited by 125 publications

(91 citation statements)

References 92 publications

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“…The commonly adopted process to manufacture ferromagnetic cores consists of stacking thin sheets of FeSi steel, coated with a dielectric material [1]. The strategy based on the use of 0.2-0.5 mm thick and coated sheets allows for interrupting the induced currents' circulation path and reduces eddy current losses [13,14]. Based on this approach, good magnetic properties are conferred to the components.…”

Section: Introductionmentioning

confidence: 99%

Properties of Additively Manufactured Electric Steel Powder Cores with Increased Si Content

et al. 2021

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In this paper, the best laser powder bed fusion (L-PBF) printing conditions for FeSi steels with two different Si content (3.0% and 6.5%) are defined. Results show very strict processing window parameters, following a lack of fusion porosity at low specific energy values and keyhole porosity in correspondence with high specific energy values. The obtained microstructure consists of grains with epitaxial growth starting from the grains already solidified in the underling layer. This allows the continuous growth of the columnar grains, directed parallel to the built direction of the component. The magnetic behaviour of FeSi6.5 samples, although the performances found do not still fully reach those of the best commercial electrical steels (used to manufacture magnetic cores of electrical machines and other similar magnetic components), appears to be quite promising. An improvement of the printing process to obtain thin sheets with increased Si content, less than 0.5 mm thick, with accurate geometry and robust structures, can result to an interesting technology for specific application where complex geometries and sophisticated shapes are required, avoiding mechanical machining processes for electrical steel with high silicon content.

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Section: Introductionmentioning

confidence: 99%

Properties of Additively Manufactured Electric Steel Powder Cores with Increased Si Content

et al. 2021

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“…Besides traditional plastic components, this process has been adopted for a wide range of industries for innovative product development including soft magnets [ 62 ], drug delivery systems in the pharmaceutical field including personalized medicines [ 63 , 64 , 65 , 66 ], in the forensic comparative analysis [ 67 ], in complete electrochemical sensing devices fabrication [ 68 ], in 3D printed microfluidics [ 69 ] and to design and manufacturing of complex porous scaffolds for biomedical, and tissue engineering applications [ 70 ]. Moreover, it also fits well in the framework of primary and secondary recycling.…”

Section: Classification Of Am Processesmentioning

confidence: 99%

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

et al. 2021

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The use of additive manufacturing (AM) has moved well beyond prototyping and has been established as a highly versatile manufacturing method with demonstrated potential to completely transform traditional manufacturing in the future. In this paper, a comprehensive review and critical analyses of the recent advances and achievements in the field of different AM processes for polymers, their composites and nanocomposites, elastomers and multi materials, shape memory polymers and thermo-responsive materials are presented. Moreover, their applications in different fields such as bio-medical, electronics, textiles, and aerospace industries are also discussed. We conclude the article with an account of further research needs and future perspectives of AM process with polymeric materials.

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“…As the main objective of this paper is to introduce the capability of the AM method in the advanced thermal management design of electrical machines; More information about the other subjects of additive manufacturing techniques in electrical machines can be found following literatures and references [1], [2], [6], [13], [14], [15], [16], [17], [18], [19], [20], [21], [22] .…”

Section: Additive Manufacturing Approachmentioning

confidence: 99%

“…In other words, requiring advanced modern techniques allow the electrical machine manufacturers to design the novel electrical machine with whatever complex shapes, structures, and advanced materials by implementing the modern computational electromagnetic, thermal, and material approaches. The demands for clean energy technologies for different applications, for instance, wind power, electric vehicle, and electric powertrain, are rising rapidly [1]. The demands metrics are mainly concentrated on high power density, high efficiency, and lightweight electrical machines [1].…”

Section: Introductionmentioning

confidence: 99%

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Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

et al. 2021

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The additive manufacturing approach is considered a new manufacturing technology method and is evolving dynamically in recent years. It is advancing and achieving as the key enabling technology in a wide range of applications, from medical sciences to the aerospace and automotive industries. This novel approach opens a new path to overcome the conventional manufacturing problems and challenges by providing more design freedom, new ranges of materials, lightweight and complex geometries. According to demands metrics such as lightweight and high power density motors. This offers clear motivation to develop the advanced thermal management method with new materials and a novel additive manufacturing (AM) approach. The paper aims to provide a comprehensive review of all the attempts in various electrical machines' thermal management methods using AM method. It considers the opportunities and challenges that designers are facing while implementing these approaches. Finally, the authors make some comments/forecasts on how the AM could improve the performance and manufacturability of the future thermal management system of electrical machines INDEX TERMS Additive manufacturing (AM), cooling systems, electrical machine, manufacturing techniques, thermal management, three-dimensional (3-D) printing, traction motors.

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Additive manufacturing of soft magnets for electrical machines—a review

Cited by 125 publications

References 92 publications

Properties of Additively Manufactured Electric Steel Powder Cores with Increased Si Content

Properties of Additively Manufactured Electric Steel Powder Cores with Increased Si Content

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

Opportunities and Challenges of Utilizing Additive Manufacturing Approaches in Thermal Management of Electrical Machines

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