Improving the soft magnetic properties of binder jet printed iron-silicon alloy through boron addition

Kumari, Geeta; Pham, Thang Q.; Suen, Hawke; Rahman, Tanzilur; Kwon, Patrick; Foster, Shanelle N.; Boehlert, C. J.

doi:10.1016/j.matchemphys.2022.127181

Cited by 4 publications

(3 citation statements)

References 21 publications

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“…It is essential to mention the influence of chemical composition and microstructural changes on the magnetic properties of components manufactured through additive manufacturing. In a study conducted by Kumary et al [ 93 ], the impact of Si and B content on the properties of Fe–Si–B alloys fabricated through binder jet printing was investigated. The Si content ranged from 3 to 5 wt.%, while the B content ranged from 0.0 to 0.25 wt.%.…”

Section: Fe–simentioning

confidence: 99%

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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Additive manufacturing (AM) is an attractive set of processes that are being employed lately to process specific materials used in the fabrication of electrical machine components. This is because AM allows for the preservation or enhancement of their magnetic properties, which may be degraded or limited when manufactured using other traditional processes. Soft magnetic materials (SMMs), such as Fe–Si, Fe–Ni, Fe–Co, and soft magnetic composites (SMCs), are suitable materials for electrical machine additive manufacturing components due to their magnetic, thermal, mechanical, and electrical properties. In addition to these, it has been observed in the literature that other alloys, such as soft ferrites, are difficult to process due to their low magnetization and brittleness. However, thanks to additive manufacturing, it is possible to leverage their high electrical resistivity to make them alternative candidates for applications in electrical machine components. It is important to highlight the significant progress in the field of materials science, which has enabled the development of novel materials such as high-entropy alloys (HEAs). These alloys, due to their complex chemical composition, can exhibit soft magnetic properties. The aim of the present work is to provide a critical review of the state-of-the-art SMMs manufactured through different AM technologies. This review covers the influence of these technologies on microstructural changes, mechanical strengths, post-processing, and magnetic parameters such as saturation magnetization (MS), coercivity (HC), remanence (Br), relative permeability (Mr), electrical resistivity (r), and thermal conductivity (k).

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Section: Fe–simentioning

confidence: 99%

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Vargas

Stornelli

Folgarait³

et al. 2023

Materials

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“…Additive manufacturing enables the fabrication of three-dimensional parts based on previously designed digital CAD models [5]. The finished object is divided into layers and the path of the tool that builds the subsequent layers is determined.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

Marczyk

Hebda

2023

Electronics

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The present work analyzed the influence of the particle size of irregular aluminum powder on the properties of Binder-Jetting-printed parts, which can be used as electronic components. Powders of various particle sizes as well as blends in the ratio of 73–27 wt.% or 27–73 wt.% of coarse to fine powder particles were used. The parts were printed with constant parameters, such as a layer thickness of 120 µm, roller traverse speed of 10 mm/s, and binder saturation of 80%. For parts made of individual blends, analysis of the XRD, density, porosity, surface roughness, and dimensional changes in X, Y, and Z axes after the sintering process was conducted. The results confirmed the trend of smoothing the surface of 3D-printed parts with a reduction in the size of the powder particles used. The best results in terms of surface roughness were obtained for powder in which coarse particles (73%) had 50 µm and fine particles (27%) had 20 µm. However, the incorporation of coarser particles in an amount of 27 wt.% (AL160) to the fine-grained powder base (ALC100) allowed for the obtaining of details with higher density, lower total porosity, and relatively low surface roughness. The combination of these two powder particle sizes allowed the fine powder to fill the voids between the larger particles, resulting in properties that represent an excellent relationship between density, porosity, and surface quality. The research results indicate that the three-dimensional parts produced by Binder Jetting technology, through the phenomenal thermal conductivity of aluminum, can be successfully used as electronic components, such as heat sinks or transistor housings.

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“…As a result, most industrial-scale Fe-Si alloys contain less than 3.5% silicon, as higher silicon levels complicate the conventional production of electrical steel sheets [140]. A lot of research has been going on to solve this problem with additive manufacturing techniques like laser-based AM techniques, including selective laser melting, powder bed fusion of metal with a laser beam, binder jet printing, and direct energy deposition [141][142][143][144][145][146][147]. Research is also ongoing in multi-material AM.…”

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confidence: 99%

The Future of Permanent-Magnet-Based Electric Motors: How Will Rare Earths Affect Electrification?

Podmiljšak,

Saje,

Jenuš

et al. 2024

Materials

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In this review article, we focus on the relationship between permanent magnets and the electric motor, as this relationship has not been covered in a review paper before. With the increasing focus on battery research, other parts of the electric system have been neglected. To make electrification a smooth transition, as has been promised by governing bodies, we need to understand and improve the electric motor and its main component, the magnet. Today’s review papers cover only the engineering perspective of the electric motor or the material-science perspective of the magnetic material, but not both together, which is a crucial part of understanding the needs of electric-motor design and the possibilities that a magnet can give them. We review the road that leads to today’s state-of-the-art in electric motors and magnet design and give possible future roads to tackle the obstacles ahead and reach the goals of a fully electric transportation system. With new technologies now available, like additive manufacturing and artificial intelligence, electric motor designers have not yet exploited the possibilities the new freedom of design brings. New out-of-the-box designs will have to emerge to realize the full potential of the new technology. We also focus on the rare-earth crisis and how future price fluctuations can be avoided. Recycling plays a huge role in this, and developing a self-sustained circular economy will be critical, but the road to it is still very steep, as ongoing projects show.

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Improving the soft magnetic properties of binder jet printed iron-silicon alloy through boron addition

Cited by 4 publications

References 21 publications

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Recent Advances in Additive Manufacturing of Soft Magnetic Materials: A Review

Effect of the Particle Size Distribution of Irregular Al Powder on Properties of Parts for Electronics Fabricated by Binder Jetting

The Future of Permanent-Magnet-Based Electric Motors: How Will Rare Earths Affect Electrification?

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