Binder Jet Printed Iron Silicon with Low Hysteresis Loss

Pham, Thang Q.; Mellak, Christiane; Suen, Hawke; Boehlert, C. J.; Muetze, Annette; Kwon, Patrick; Foster, Shanelle N.

doi:10.1109/iemdc.2019.8785256

Cited by 8 publications

(5 citation statements)

References 15 publications

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“…As a result, iron cores prepared with BJP process can be suitable for applications where easy flux flow in three dimensions is preferred. Hysteresis loss of BJP iron-silicon can be further reduced with the addition of boron into the starting powder [43,44]. This can be explained by the increase of 40% in average grain size of BJP iron-silicon with the addition of boron.…”

Section: Iron-silicon (Fesi)mentioning

confidence: 97%

“…Table 1. Comparison of grain size and maximum relative permeability between as-built and heattreated printed soft magnetic materials [34,37,40,43,45].…”

Section: Performance Of Additively Manufactured Soft Magnetic Materialsmentioning

confidence: 99%

“…Iron loss characteristics of printed FeSi is still a major concern. At DC or quasi-static excitation, additive manufactured iron-silicon has been shown to achieve hysteresis loss comparable to iron-silicon laminations [43]. The intrinsic coercivity of SLM-processed and BJP-processed FeSi is nearly 4 times lower than SMCs.…”

Section: Challengesmentioning

confidence: 99%

“…These iron loss values at low frequency range, however, are promising providing that this is still at an early stage of applying AM for soft magnetic materials. As the excitation frequency increases, however, the total iron loss of 3D printed iron-silicon increases exponentially [43]. The resistivity and eddy current loss of 3D printed iron-silicon must be reduced.…”

Section: Challengesmentioning

confidence: 99%

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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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Section: Iron-silicon (Fesi)mentioning

confidence: 97%

“…Table 1. Comparison of grain size and maximum relative permeability between as-built and heattreated printed soft magnetic materials [34,37,40,43,45].…”

Section: Performance Of Additively Manufactured Soft Magnetic Materialsmentioning

confidence: 99%

Section: Challengesmentioning

confidence: 99%

Section: Challengesmentioning

confidence: 99%

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

2021

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“…However, different cutting directions can also be chosen to measure anisotropy. Th 3D-printed iron core strips can be cut from the printed material to construct the frame [85]. Primary and secondary winding arrangements are placed on each side of the frame.…”

Section: Epstein Framementioning

confidence: 99%

Iron Loss Calculation Methods for Numerical Analysis of 3D-Printed Rotating Machines: A Review

Orosz,

Horváth,

Tóth

et al. 2023

Energies

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Three-dimensional printing is a promising technology that offers increased freedom to create topologically optimised electrical machine designs with a much smaller layer thickness achievable with the current, laminated steel-sheet-based technology. These composite materials have promising magnetic behaviour, which can be competitive with the current magnetic materials. Accurately calculating the iron losses is challenging due to magnetic steels’ highly nonlinear hysteretic behaviour. Many numerical methodologies have been developed and applied in FEM-based simulations from the first introduced Steinmetz formulae. However, these old curve-fitting-based iron loss models are still actively used in modern finite-element solvers due to their simplicity and high computational demand for more-accurate mathematical methods, such as Preisach- or Jiles–Atherton-model-based calculations. In the case of 3D-printed electrical machines, where the printed material can have a strongly anisotropic behaviour and it is hard to define a standardised measurement, the applicability of the curve-fitting-based iron loss methodologies is limited. The following paper proposes an overview of the current problems and solutions for iron loss calculation and measurement methodologies and discusses their applicability in designing and optimising 3D-printed electrical machines.

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WITHDRAWN: Binder jet 3D printing – Process parameters, materials, properties, and challenges

Mostafaei

Elliott

Barnes

et al. 2020

Progress in Materials Science

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Binder Jet Printed Iron Silicon with Low Hysteresis Loss

Cited by 8 publications

References 15 publications

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

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

Iron Loss Calculation Methods for Numerical Analysis of 3D-Printed Rotating Machines: A Review

WITHDRAWN: Binder jet 3D printing – Process parameters, materials, properties, and challenges

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