The effect of particle size on the core losses of soft magnetic composites

Pošković, Emir; Ferraris, Luca; Franchini, Fausto; Grande, Marco Actis

doi:10.1063/1.5080079

Cited by 10 publications

(6 citation statements)

References 30 publications

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“…Various ferromagnetic powders can be coated with epoxy resin [124,125]. Particles size [20], resin content [126], and molding pressures [127] strongly impact the SMCs performances. In Pošković et al [126], the minimum epoxy content weight was strongly reduced to 0.05 wt.%.…”

Section: Epoxy Resinsmentioning

confidence: 99%

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Recent Advances in Multi-Functional Coatings for Soft Magnetic Composites

et al. 2021

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During the past 50 years, the aim to reduce the eddy current losses in magnetic cores to a minimum led to the formulation of new materials starting from electrically insulated iron powders, today called Soft Magnetic Composites (SMC). Nowadays, this promising branch of materials is still held back by the mandatory tradeoff between energetic, electrical, magnetic, and mechanical performances. In most cases, the research activity focuses on the deposition of an insulating/binding layer, being one of the critical points in optimizing the final composite. This insulation usually is achieved by either inorganic or organic layer constituents. The main difference is the temperature limit since most inorganic materials typically withstand higher treatment temperatures. As a result, the literature shows many materials and process approaches, each one designed to meet a specific application. The present work summarizes the recent advances in state of the art, analyzing the relationship among material compositions and magnetic and mechanical properties. Each coating shows its own processing sets, which vary from simple mechanical mixing to advanced chemical methods to metallurgical treatments. From state of the art, Aluminum coatings are characterized by higher current losses and low mechanical properties. In contrast, higher mechanical properties are obtained by adopting Silicon coatings. The phosphates coatings show the best-balanced overall properties. Each coating type was thoroughly investigated and then compared with the literature background highlighting. The present paper thus represents a critical overview of the topic that could serve as a starting point for the design and development of new and high-performing coating solutions for SMCs. However, global research activity continuously refines the recipes, introducing new layer materials. The following steps and advances will determine whetherthese materials breakthrough in the market.

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Section: Epoxy Resinsmentioning

confidence: 99%

“…The granulometry of the powders [19,20] and the number of pores [21] in the final component are critical parameters in the SMC mixes. As for the latter, it is well known [22][23][24] that pores act as crack initiators.…”

Section: Introductionmentioning

confidence: 99%

Recent Advances in Multi-Functional Coatings for Soft Magnetic Composites

et al. 2021

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“…The mechanical strength is dependent on fractions matching the medium and large particle sizes. Hybrid Magnetic Composites (HMC) [69][70][71] made of a mixture of soft and hard magnetic powder materials having a polymer binder provides mechanical strength and they are promising materials. HMCs are very small manipulative permanent magnets and can be used to replace AlNiCo and ferrite magnets.…”

Section: Magnetic Materialsmentioning

confidence: 99%

A Review on Methods to Reduce Weight and to Increase Efficiency of Electric Motors Using Lightweight Materials, Novel Manufacturing Processes, Magnetic Materials and Cooling Methods

Solomon¹,

Greco²,

Masselli³

et al. 2020

ACSM

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The electric motor is the mechanism that transforms electrical energy into mechanical energy. Nowadays, electric motors are the cause of a considerable share of the use of electricity and therefore of the energy consumptions (70% in the industrial sector and 25-30% in the tertiary sector). Faced with ever-increasing energy demand and with a view to adhering to the all-over-the world imperative of adopting measures to reduce energy consumption in all the involved sectors, the use of efficiency enhanced electric motors is required. Generally, the efficiency of an electric motor depends on the type of motor, the size of the motor, the utilization factor, but also on the quality and quantity of the materials employed. Therefore, from all these aspects the need of using energy and costefficient components for developing electric motors arises. This review paper aims to draw a general framework on the methods of increasing efficiency and of reducing weight of the electric motors.

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“…As a result of their use, the destruction the material's internal structure, resulting from the implementation of the mechanical laser cutting process (manifested by the deterioration of the material's magnetic prop ties), is avoided. Referring to additive manufacturing methods, a group of works descr ing research conducted on sintered materials can be identified [8][9][10][11][12][13][14][15], as well as a gro of works depicting the research results using laser powder bed fusion technology As the published research results on SMC and LPBF materials indicate, they can be us mainly in motors operating at frequencies of kHz and higher. Then, the low specific ir loss of the material about the Fe-Si laminates, which the authors of this article deal w Hence, there is a common interest in both the problem of the exact description of core losses and the search for methods to reduce them.…”

Section: Introductionmentioning

confidence: 99%

“…As a result of their use, the destruction of the material's internal structure, resulting from the implementation of the mechanical or laser cutting process (manifested by the deterioration of the material's magnetic properties), is avoided. Referring to additive manufacturing methods, a group of works describing research conducted on sintered materials can be identified [8][9][10][11][12][13][14][15], as well as a group of works depicting the research results using laser powder bed fusion technology [16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

2023

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The global drive to reduce energy consumption poses new challenges for designers of electrical machines. Losses in the core are a significant part of losses, especially for machines operating at an increased rotational speed powered by PWM inverters. One of the important problems when calculating core losses is considering the effect of material degradation due to mechanical or laser cutting. To this aim, this paper analyzes and summarizes the knowledge about the sources of material property deterioration and ways of describing this phenomenon. The cited results of material tests indicate the lack of unequivocal relationships allowing us to estimate the degree of material damage and the resulting deterioration of material properties. The main task of this article is to present the state of knowledge on the possibility of taking into account the impact of cutting the core sheets of electric motors on core losses and their impact on the efficiency of the machine. This is a significant problem due to the need to design and manufacture energy-saving electric motors powered with a voltage of 20 to 350 Hz, whose magnetic cores are made of laminates. However, the performed analysis indicates the most important parameters of the cutting process, affecting the degree of material structure destruction. The method of the solution proposed by the authors for core punching and laser cutting, illustrated with a practical example, is also presented.

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The effect of particle size on the core losses of soft magnetic composites

Cited by 10 publications

References 30 publications

Recent Advances in Multi-Functional Coatings for Soft Magnetic Composites

Recent Advances in Multi-Functional Coatings for Soft Magnetic Composites

A Review on Methods to Reduce Weight and to Increase Efficiency of Electric Motors Using Lightweight Materials, Novel Manufacturing Processes, Magnetic Materials and Cooling Methods

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

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