Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications
Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been in...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-05-01
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| Series: | Energies |
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| Online Access: | https://www.mdpi.com/1996-1073/15/10/3665 |
| _version_ | 1797500168254259200 |
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| author | Hans Tiismus Ants Kallaste Toomas Vaimann Liina Lind Indrek Virro Anton Rassõlkin Tatjana Dedova |
| author_facet | Hans Tiismus Ants Kallaste Toomas Vaimann Liina Lind Indrek Virro Anton Rassõlkin Tatjana Dedova |
| author_sort | Hans Tiismus |
| collection | DOAJ |
| description | Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by the electrical machine (EM) research community to develop and integrate novel additive components. Several challenges remain, however, in printing soft magnetic flux guides—most prominently, reducing the induced eddy currents to achieve competitive AM core efficiency. This paper demonstrates the workflow of laser additive manufacturing magnetic cores with superior magnetic properties to soft magnetic composites (at 50 Hz excitation): describing the workflow, parameter tuning for both printing and annealing, and shape optimization. Process optimization yielded the optimal energy density of 77 J/mm<sup>3</sup> and annealing temperature of 1200 °C, applied to prepare the samples with the highest relative density (99.86%), lowest surface roughness R<sub>z</sub> (0.041 mm), minimal hysteresis losses (0.8 W/kg at 1.0 T, 50 Hz), and ultimate yield strength of 420 MPa. For Eddy current suppression, the sample (5 × 5 × 60 mm toroid) with bi-directional grading reached specific core losses as low as 1.8 W/kg (W<sub>10,50</sub>). Based on the findings, the advantages and disadvantages of AM graded cores are discussed in detail. |
| first_indexed | 2024-03-10T03:58:00Z |
| format | Article |
| id | doaj.art-608c53dec31c4acda571566f003a374a |
| institution | Directory Open Access Journal |
| issn | 1996-1073 |
| language | English |
| last_indexed | 2024-03-10T03:58:00Z |
| publishDate | 2022-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Energies |
| spelling | doaj.art-608c53dec31c4acda571566f003a374a2023-11-23T10:51:23ZengMDPI AGEnergies1996-10732022-05-011510366510.3390/en15103665Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine ApplicationsHans Tiismus0Ants Kallaste1Toomas Vaimann2Liina Lind3Indrek Virro4Anton Rassõlkin5Tatjana Dedova6Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaDepartment of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaInstitute of Forestry and Engineering, Estonian University of Life Sciences, Fr. R. Kreutzwaldi 1, 51006 Tartu, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaDepartment of Materials Science, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, EstoniaAdditive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by the electrical machine (EM) research community to develop and integrate novel additive components. Several challenges remain, however, in printing soft magnetic flux guides—most prominently, reducing the induced eddy currents to achieve competitive AM core efficiency. This paper demonstrates the workflow of laser additive manufacturing magnetic cores with superior magnetic properties to soft magnetic composites (at 50 Hz excitation): describing the workflow, parameter tuning for both printing and annealing, and shape optimization. Process optimization yielded the optimal energy density of 77 J/mm<sup>3</sup> and annealing temperature of 1200 °C, applied to prepare the samples with the highest relative density (99.86%), lowest surface roughness R<sub>z</sub> (0.041 mm), minimal hysteresis losses (0.8 W/kg at 1.0 T, 50 Hz), and ultimate yield strength of 420 MPa. For Eddy current suppression, the sample (5 × 5 × 60 mm toroid) with bi-directional grading reached specific core losses as low as 1.8 W/kg (W<sub>10,50</sub>). Based on the findings, the advantages and disadvantages of AM graded cores are discussed in detail.https://www.mdpi.com/1996-1073/15/10/3665additive manufacturingelectrical machinessoft magnetic materialshysteresis losseddy current lossannealing |
| spellingShingle | Hans Tiismus Ants Kallaste Toomas Vaimann Liina Lind Indrek Virro Anton Rassõlkin Tatjana Dedova Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications Energies additive manufacturing electrical machines soft magnetic materials hysteresis loss eddy current loss annealing |
| title | Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications |
| title_full | Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications |
| title_fullStr | Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications |
| title_full_unstemmed | Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications |
| title_short | Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications |
| title_sort | laser additively manufactured magnetic core design and process for electrical machine applications |
| topic | additive manufacturing electrical machines soft magnetic materials hysteresis loss eddy current loss annealing |
| url | https://www.mdpi.com/1996-1073/15/10/3665 |
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