Structurally-layered soft magnetic Fe-Si components with surface insulation prepared by shell-shaping selective laser melting

Koo, Bonuk; Jang, Min-Sun; Nam, Yeong Gyun; Yang, Sangsun; Yu, Juan; Park, Taesung; Jeong, Jae Won

doi:10.1016/j.apsusc.2021.149510

Cited by 31 publications

(12 citation statements)

References 14 publications

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“…applied 93 J/mm 3 (70 W; 500 mm/s; 60 µm; 25 µm) to fuse 98.5% dense parts from 6.9% silicon steel. In [43], a considerably higher energy density of 225 J/mm 3 (90 W; 200 mm/s; 80 µm; 25 µm) was applied to fuse 6.5% silicon content parts with above 98% relative density. Similarly, Goll et.…”

Section: Discussionmentioning

confidence: 99%

Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications

et al. 2022

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Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by the electrical machine (EM) research community to develop and integrate novel additive components. Several challenges remain, however, in printing soft magnetic flux guides—most prominently, reducing the induced eddy currents to achieve competitive AM core efficiency. This paper demonstrates the workflow of laser additive manufacturing magnetic cores with superior magnetic properties to soft magnetic composites (at 50 Hz excitation): describing the workflow, parameter tuning for both printing and annealing, and shape optimization. Process optimization yielded the optimal energy density of 77 J/mm3 and annealing temperature of 1200 °C, applied to prepare the samples with the highest relative density (99.86%), lowest surface roughness Rz (0.041 mm), minimal hysteresis losses (0.8 W/kg at 1.0 T, 50 Hz), and ultimate yield strength of 420 MPa. For Eddy current suppression, the sample (5 × 5 × 60 mm toroid) with bi-directional grading reached specific core losses as low as 1.8 W/kg (W10,50). Based on the findings, the advantages and disadvantages of AM graded cores are discussed in detail.

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Section: Discussionmentioning

confidence: 99%

Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications

et al. 2022

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“…One study by Koo et al introduced a novel shell-shaping selective laser melting (SS-SLM) approach to develop structurally layered Fe-Si parts with a thin surface insulation coating between layers. 151 Fe-6.5 wt.%Si powder was utilized in an SLM machine to construct specimens with internal shells aligned vertically from the build plate substrate. The internal shell thickness, analogous to rolled sheet thickness in conventional laminated cores, varied from 0.2 mm to 1 mm.…”

Section: Additive Manufacturingmentioning

confidence: 99%

Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Kustas

Susan

Monson

2022

JOM

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Soft-magnetic alloys exhibit exceptional functional properties that are beneficial for a variety of electromagnetic applications. These alloys are conventionally manufactured into sheet or bar forms using well-established insgot metallurgy practices that involve hot- and cold-working steps. However, recent developments in process metallurgy have unlocked opportunities to directly produce bulk soft-magnetic alloys with improved, and often tailorable, structure–property relationships that are unachievable conventionally. The emergence of unconventional manufacturing routes for soft-magnetic alloys is largely motivated by the need to improve the energy efficiency of electromagnetic devices. In this review, literature that details emerging manufacturing approaches for soft-magnetic alloys is overviewed. This review covers (1) severe plastic deformation, (2) recent advances in melt spinning, (3) powder-based methods, and (4) additive manufacturing. These methods are discussed in comparison with conventional rolling and bar processing. Perspectives and recommended future research directions are also discussed.

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“…induction motors) due to its low magnetocrystalline anisotropy, high resistivity and near-zero magnetostriction (Bozorth, 1978). Most of the previous studies on additively manufactured Fe-3Si alloys are performed on bulk solid materials (Garibaldi et al , 2016; Lemke et al , 2017; Garibaldi et al , 2018, 2018; Koo et al , 2021; Stornelli et al , 2021). Here, most of the studies are performed on additively manufactured Fe6.5Si or Fe6.9Si alloys, as a major benefit of processing Fe-3Si alloys by additive manufacturing (AM) is the processing of complex-shaped parts.…”

Section: Introductionmentioning

confidence: 99%

Experimental and finite element method investigation on the compression behaviour of FCCZ and BCC lattice structures of additively manufactured Fe-3Si samples

Pramanik

Hoyer

Schaper

2023

RPJ

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Purpose The purpose of this study is to investigate the manufacturability of Fe-3Si lattice structures and the resulting mechanical properties. This study could lead to the successful processing of squirrel cage conductors (a lattice structure by design) of an induction motor by additive manufacturing in the future. Design/methodology/approach The compression behaviour of two lattice structures where struts are arranged in a face-centred cubic position and vertical edges (FCCZ), and struts are placed at body-centred cubic (BCC) positions, prepared by laser powder bed fusion (LPBF), is explored. The experimental investigations are supported by finite element method (FEM) simulations. Findings The FCCZ lattice structure presents a peak in the stress-strain curve, whereas the BCC lattice structure manifests a plateau. The vertical struts aligned along the compression direction lead to a significant increase in the load-carrying ability of FCCZ lattice structures compared to BCC lattice structures. This results in a peak in the stress-strain curve. However, the BCC lattice structure presents the bending of struts with diagonal struts carrying the major loads with struts near the faceplate receiving the least load. A high concentration of geometrically necessary dislocations (GNDs) near the grain boundaries along cell formation is observed in the microstructure. Originality/value To the best of the authors’ knowledge, this is the first study on additive manufacturing of Fe-3Si lattice structures. Currently, there are no investigations in the literature on the manufacturability and mechanical properties of Fe-3Si lattice structures.

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Structurally-layered soft magnetic Fe-Si components with surface insulation prepared by shell-shaping selective laser melting

Cited by 31 publications

References 14 publications

Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications

Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications

Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Experimental and finite element method investigation on the compression behaviour of FCCZ and BCC lattice structures of additively manufactured Fe-3Si samples

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