Additive manufacturing of soft magnetic materials and components

Goll, D.; Schuller, David E.; Martinek, G.; Kunert, Torsten; Schurr, Julian; Sinz, C.; Schubert, Tim; Bernthaler, Timo; Riegel, Harald; Schneider, Gerhard

doi:10.1016/j.addma.2019.02.021

Cited by 113 publications

(111 citation statements)

References 28 publications

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“…All of the above considerations lead to concluding that this kind of alloy requires being printed at a low enough laser energy input to avoid transition or keyhole regimes, preventing both porosities and cracks. Absorptivity, printing modes' limits (conduction and keyhole), and porosity, derived through numerical modeling of the processes described in [10] and [13], referring to steels with 6.7% and 6.9% Si. Absorptivity, printing modes' limits (conduction and keyhole), and porosity, derived through numerical modeling of the processes described in [10,13], referring to steels with 6.7% and 6.9% Si.…”

Section: Methodsmentioning

confidence: 99%

“…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%

“…Up to now, the scientific research on the production of magnetic materials and components through Additive Manufacturing technology is quite young [ 13 ]; however, the possibility of producing complex and more performing components represents a powerful technology drive to innovate the production of ferromagnetic cores and meet the challenging requests from the electric traction sector and, in general, from electric propulsion transport [ 46 , 47 ]. The contributions present in the literature refer to the experimental manufacture of ferromagnetic cores in FeSi steel with Si content between 6.7 wt.% and 6.9 wt.% [ 9 , 10 , 12 , 13 , 48 ] and are focused on setting the parameters of the melting process (e.g., laser power and scan speed) to minimize the porosity and produce components with high magnetic properties. Some strategies [ 13 ] concern the building of ferromagnetic cores having internal geometry with slits or the alternation of materials of different nature.…”

Section: Introductionmentioning

confidence: 99%

“…The contributions present in the literature refer to the experimental manufacture of ferromagnetic cores in FeSi steel with Si content between 6.7 wt.% and 6.9 wt.% [ 9 , 10 , 12 , 13 , 48 ] and are focused on setting the parameters of the melting process (e.g., laser power and scan speed) to minimize the porosity and produce components with high magnetic properties. Some strategies [ 13 ] concern the building of ferromagnetic cores having internal geometry with slits or the alternation of materials of different nature. In this way, the presence of air inside the slits or a low conductivity material emulates the behavior of the dielectric materials typically used in conventional production.…”

Section: Introductionmentioning

confidence: 99%

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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: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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“…The printing of several different materials using selective laser melting (SLM) is available in the literature. The SLM fabrication of conductive (Cu [10], AISi10MG [11]) and soft ferromagnetic (FeSi6.7 [12], FeSi6.9 [13], FeSi3 [14], Fe-Co-V [15], Fe-Ni-Si [16]) materials are well explained in the literature.…”

Section: Introductionmentioning

confidence: 99%

Sliding Mean Value Subtraction-Based DC Drift Correction of B-H Curve for 3D-Printed Magnetic Materials

et al. 2021

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This paper presents an algorithm to remove the DC drift from the B-H curve of an additively manufactured soft ferromagnetic material. The removal of DC drift from the magnetization curve is crucial for the accurate estimation of iron losses. The algorithm is based on the sliding mean value subtraction from each cycle of calculated magnetic flux density (B) signal. The sliding mean values (SMVs) are calculated using the convolution theorem, where a DC kernel with a length equal to the size of one cycle is convolved with B to recover the drifting signal. The results are based on the toroid measurements made by selective laser melting (SLM)-based 3D printing mechanism. The measurements taken at different flux density values show the effectiveness of the method.

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