In-Situ Magnetization of a Cold Sprayed Permanent Magnet Rotor Using an Impulse Magnetizer

Boby, Mathews; Singh, Sumeet; Lamarre, J.-M.; Ibrahim, Maged; Bernier, Fabrice; Pillay, Pragasen

doi:10.1109/iecon48115.2021.9589877

Cited by 2 publications

(1 citation statement)

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“…In addition, the additive manufacturing of structural parts has also been considered in this project. The additive manufacturing of the hard magnetic parts has been discarded because, for the time being, except for very specific AM processes such as cold spray [37][38][39], the magnetic performance (coercivity, remanence) of the resulting magnets is far from that of conventional sintered rare earth magnets [40][41][42][43]. Additive manufacturing of copper coils has also not been considered due to the small size of the actuator and the high number of turns that the near-zero speed requires to achieve the desired voltage.…”

Section: Motor Brake and Resolvermentioning

confidence: 99%

Electric Aerospace Actuator Manufactured by Laser Powder Bed Fusion

Lizarribar,

Prieto,

Aristizabal

et al. 2023

Aerospace

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Recent advances in manufacturing methods have accelerated the exploration of new materials and advantageous shapes that could not be produced by traditional methods. In this context, additive manufacturing is gaining strength among manufacturing methods for its versatility and freedom in the geometries that can be produced. Taking advantage of these possibilities, this research presents a case study involving an electric aerospace actuator manufactured using additive manufacturing. The main objectives of this research work are to assess the feasibility of additively manufacturing electric actuators and to evaluate potential gains in terms of weight, volume, power consumption and cost over conventional manufacturing technologies. To do so and in order to optimise the actuator design, a thorough material study is conducted in which three different magnetic materials are gas-atomised (silicon iron, permendur and supermalloy) and test samples of the most promising materials (silicon iron and permendur) are processed by laser powder bed fusion. The final actuator design is additively manufactured in permendur for the stator and rotor iron parts and in 316L stainless steel for the housing. The electric actuator prototype is tested, showing compliance with design requirements in terms of torque production, power consumption and heating. Finally, a design intended to be manufactured via traditional methods (i.e., punching and stacking for the stator laminations and machining for the housing) is presented and compared to the additively manufactured design. The comparison shows that additive manufacturing is a viable alternative to traditional manufacturing for the application presented, as it highly reduces the weight of the actuator and facilitates the assembly, while the cost difference between the two designs is minimal.

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