Additive Manufacturing of a Soft Magnetic Rotor Active Part and Shaft for a Permanent Magnet Synchronous Machine

Urbanek, Stefan; Ponick, Bernd; Taube, Alexander L.; Hoyer, Kay-Peter; Schaper, Mirko; Lammers, Stefan; Lieneke, Tobias; Zimmer, Detmar

doi:10.1109/itec.2018.8450250

Cited by 29 publications

(6 citation statements)

References 14 publications

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“…At last, it is worth noting initial trials in combining distinct functionalities. Urbanek et al [218] described the design and additively manufactured a soft magnetic rotor together with a shaft for a permanent magnet synchronous machine. To achieve electromagnetic requirements, ferromagnetic materials including ferro-silicon and ferro-cobalt alloys were additively processed with microstructures shown in Fig.…”

Section: Energy Harvestermentioning

confidence: 99%

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

et al. 2022

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Magnetic materials are of increasing importance for many essential applications due to their unique magnetic properties. However, due to the limited fabrication ability, magnetic materials are restricted by simple geometric shapes. Three-dimensional (3D) printing is a highly versatile technique that can be utilized for constructing magnetic materials. The shape flexibility of magnets unleashes opportunities for magnetic composites with reducing post-manufacturing costs, motivating the review on 3D printing of magnetic materials. This paper focuses on recent achievements of magnetic materials using 3D printing technologies, followed by the characterization of their magnetic properties, which are further enhanced by modification. Interestingly, the corresponding properties depend on the intrinsic nature of starting materials, 3D printing processing parameters, and the optimized structural design. More emphasis is placed on the functional applications of 3D-printed magnetic materials in different fields. Lastly, the current challenges and future opportunities are also addressed.

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Section: Energy Harvestermentioning

confidence: 99%

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

et al. 2022

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“…At the current stage, the majority of AM technologies are employed for single components, using a single material for printing. The printed components are then assembled together with conventionally manufactured components to form the electrical machines [85,86]. Challenges in printing multiple materials are due to the dissimilarities in characteristics of the materials.…”

Section: Multi-materials Am For Electrical Machinesmentioning

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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“…The highest maturity level in terms of LPBF processability has been reached with electrical steel compositions [8]. So far, several works have been published with Fe2.9wt.%Si [28][29][30], Fe3wt.%Si [20,22,24,31], Fe3.7wt.%Si [32,33], Fe6.5wt.%Si [20,23,31,34,35], Fe6.7wt.%Si [36], Fe6.9wt.%Si [37][38][39][40],…”

Section: Introductionmentioning

confidence: 99%

“…Recently, controlled stochastic cracking has been investigated as a viable way to better manipulate the magnetic properties of Fe6.5wt.%Si, even though for structural parts cracking represents a detrimental issue [34]. Other woks demonstrated that LPBF can be successfully adopted to realize large scale prototypes, such as rotors for electric motors [29,30,32,41,42] or transformers [20,21] made of electrical steels. An innovative application for these materials is the production of electromagnetic shields.…”

Section: Introductionmentioning

confidence: 99%

Electromagnetic shielding properties of LPBF produced Fe2.9wt.%Si alloy

et al. 2023

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Ferromagnetic materials are used in various applications: such as rotating electrical machines, wind turbines, electromagnetic shielding, transformers, and electromagnets. Compared to hard magnetic materials, their hysteresis cycles are featured by low values of coercive magnetic field and high permeability. The application of additive manufacturing to ferromagnetic materials is gaining more and more attraction. Indeed, thanks to a wider geometrical freedom, new topological optimized shapes for stator/rotor shapes can be addressed to enhance electric machines performances. However, the properties of the LPBF processed alloy compared to conventionally produced counterpart must be still addressed. Accordingly, this paper presents for the first time the use of the Laser Powder Bed Fusion (LPBF) for the manufacturing of Fe2.9wt.%Si electromagnetic shields. The process parameter selection material microstructure and the magnetic shielding factor are characterized.

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Additive Manufacturing of a Soft Magnetic Rotor Active Part and Shaft for a Permanent Magnet Synchronous Machine

Cited by 29 publications

References 14 publications

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

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

Electromagnetic shielding properties of LPBF produced Fe2.9wt.%Si alloy

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