State of the art of additively manufactured electromagnetic materials for topology optimized electrical machines

Additively Manufactured Transverse Flux Machine Components with Integrated Slits for Loss Reduction

“…The narrow slits, on the other hand, are less continuous due to the manufacturing process, resulting in spatially larger eddy currents due to bridges between the slits. These results are consistent with other studies where the integration of slits oriented along the flux direction in 3%SiFe ring samples also resulted in lower iron losses [23][24][25][26][27]. However, the slits in these studies are provided with several bridges due to mechanical stability and therefore not continuous.…”

Design principles for a single-process 3D-printed stacked dielectric actuators — Theory and experiment

“…14. The active area 𝐴 affects the stiffness (37)- (40) and the mass (30)- (33) of each active unit (single dielectric layer) and the generated force (3) due to the electromechanical coupling.…”

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

“…The additive manufacturing (AM) technologies market is constantly growing as reported in [1,2]. One of the recent application fields of AM is the e-mobility industry, where the constant need of electric machines development and optimization perfectly matches with the potentialities enabled by AM technologies [3][4][5][6][7][8][9][10]. Among others, laser powder bed fusion (LPBF) emerges as one of the most suitable AM processes to deal with the e-mobility materials [11][12][13].…”

“…Among others, laser powder bed fusion (LPBF) emerges as one of the most suitable AM processes to deal with the e-mobility materials [11][12][13]. As a matter of fact, thanks to the action of a laser beam with spots typically less than 100 µm, the production of 3D parts with intricate shapes and designs is enabled, such as ferromagnetic iron cores with engineered flux path [4-6, 8, 14] or aluminum/copper windings with custom shapes and integrated cooling channels to maximize the performances of next-generation electric motors [4][5][6][7][8]15]. Specifically, to produce soft magnetic iron cores, which find innumerous applications for rotors [16,17], stators [18,19], transformers [20,21] or linear actuators [5], the most common alloys employed are Fe-Si (electrical steel), Fe-Ni or Fe-Co alloys, ferrites and amorphous alloys.…”

“…The choice of the alloy composition highly depends on the tradeoff between price and magnetic properties achievable. In the low-frequency application spectrum (50)(51)(52)(53)(54)(55)(56)(57)(58)(59)(60), the combination of low price, low power losses and high saturation polarization and permeability of electrical steels justifies their extensive use in the production of electromagnetic devices [8,[22][23][24]. For low frequency applications Fe-Ni/Fe-Co alloys can be used [25][26][27], but usually at the expense of a higher purchase price or lower magnetic properties.…”