Permanent Magnets Produced by Cold Spray Additive Manufacturing for Electric Engines

Lamarre, J.-M.; Bernier, Fabrice

doi:10.1007/s11666-019-00917-6

Cited by 31 publications

(10 citation statements)

References 12 publications

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“…AM techniques employ layer-by-layer deposition in three dimensions, assisted by computer-aided design (CAD) [6,7]. AM techniques are promising for accelerated manufacturing of low cost bonded magnets s [8][9][10][11], in which magnet powders are blended into a binder such as polymers [10,15] Researchers have already utilized 3D printing techniques for loaded polymers [8,10,[12][13][14][15]. AM bonded magnets can be produced in easily customizable sizes and geometries at near-net-shape [16,17].…”

Section: Introductionmentioning

confidence: 99%

“…70 vol.% loading of isotropic Nd-Fe-B in nylon-12 has been achieved with an energy product of 7.25 MGOe (57.7 kJ/m 3 ) at room temperature [11]. Cold spray AM bonded magnets have achieved superior mechanical properties when compared to conventionally produced (injection and compression molded), BAAM, and AM powder bed infusion bonded magnets [15]. Selected laser melting has been demonstrated to 3D print nearly dense Nd-Fe-B magnets [19].…”

Section: Introductionmentioning

confidence: 99%

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Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Khazdozian¹,

Li²,

Paranthaman³

et al. 2018

JOM

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Additive manufacturing techniques for fabricating bonded magnets have the potential to reduce manufacturing cost and time-to-market of products and address the criticality of rare-earth elements (REEs), which is a concern for economic design of dependent applications such as permanent magnet machines. We investigated the magnetic alignment of anisotropic bonded magnet material comprising 65 vol.% Nd-Fe-B in nylon-12 produced by extrusion in a 20-W brushless direct current surface permanent magnet motor for submersible water pump application using finite element analysis. The results predict that sufficient alignment for this application could be obtained at low alignment fields (μ0H ≤ 1 T) with a reduction in the volume of critical materials by up to 40% compared with isotropic permanent magnets. This demonstrates the economic feasibility of incorporating a magnetic alignment field source into additive manufacturing systems for bonded magnets, and the potential of aligned anisotropic bonded magnets to address REE criticality.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Khazdozian¹,

Li²,

Paranthaman³

et al. 2018

JOM

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“…With ceramics as insulation material, the coil can withstand a temperature of up to 300 • C [45]. In [46][47][48], a conical air-gap machine is additively manufactured for automotive traction as shown in Figure 18. A complete PM rotor is 3D printed using cold spray technology with NdFeB-Al composite powder.…”

Section: Complete Machine Partsmentioning

confidence: 99%

“…Figure18. Additively manufactured PM rotor for a conical air-gap machine using cold spray technology[46][47][48].…”

mentioning

confidence: 99%

Metal Additive Manufacturing for Electrical Machines: Technology Review and Latest Advancements

2022

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Metal additive manufacturing (AM) has been growing remarkably in the past few years. Thanks to the advantages of unmatched flexibility and zero material waste, this clean technology opens the door for new design solutions with greater material efficiency, which are not possible through conventional machining techniques. In this paper, we provide a technology overview of metal AM techniques that can be utilized in a wide range of applications, including constructing electrical machines. Different techniques of metal AM are discussed and compared. Additionally, the impact of the material forms (powder/wire) on printing speed and quality are studied. Based on the industrial and technical literature, this paper provides a comprehensive review of metal AM in the fabrication of electrical machines and their applications. This includes the current state of the art and associated benefits of AM in these applications.

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“…It is a novel three-dimensional (3D) materials printing technology in a layer-by-layer fashion. There are several approaches of implementing the AM of the PMs, such as fused deposition modeling (FDM) [ 1 , 2 , 3 , 4 , 5 , 6 ], selective powder-bed fusion using laser also known as selective laser melting (SLM) [ 7 ], spark plasma sintering (SPS) [ 8 ], cold spray (CS) [ 9 ], stereolithography (SL) [ 10 ], direct energy deposition (DED) [ 11 ], vat photopolymerization [ 12 ], laminated object manufacturing (LOM) [ 13 ], and binder jetting technology (BJT) [ 14 ]. Extrusion deposition: FDM based AM of bonded PMs have demonstrated useful metrics in terms of energy density, flexural strength, and lower eddy current loss [ 2 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Isotropic NdFeB PPS Bonded Permanent Magnets

et al. 2020

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Extrusion based additive manufacturing of polymer composite magnets can increase the solid loading volume fraction with greater mechanical force through the printing nozzle as compared to traditional injection molding process. About 63 vol% of isotropic NdFeB magnet powders were compounded with 37 vol% of polyphenylene sulfide and bonded permanent magnets were fabricated while using Big Area Additive Manufacturing without any degradation in magnetic properties. The polyphenylene sulfide bonded magnets have a tensile stress of 20 MPa, almost double than that of nylon bonded permanent magnets. Additively manufactured and surface-protective-resin coated bonded magnets meet the industrial stability criterion of up to 175 °C with a flux-loss of 2.35% over 1000 h. They also exhibit better corrosion resistance behavior when exposed to acidic (pH = 1.35) solution for 24 h and also annealed at 80 °C over 100 h (at 95% relative humidity) over without coated magnets. Thus, polyphenylene sulfide bonded, additively manufactured, protective resin coated bonded permanent magnets provide better thermal, mechanical, and magnetic properties.

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Permanent Magnets Produced by Cold Spray Additive Manufacturing for Electric Engines

Cited by 31 publications

References 12 publications

Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Metal Additive Manufacturing for Electrical Machines: Technology Review and Latest Advancements

Additive Manufacturing of Isotropic NdFeB PPS Bonded Permanent Magnets

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