Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets
High silicon (Si) electrical steel has the potential for efficient use in applications such as electrical motors and generators with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% be...
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| Format: | Article |
| Language: | English |
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Elsevier
2019-11-01
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| Series: | Heliyon |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2405844019364643 |
| _version_ | 1818409926036291584 |
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| author | Corson L. Cramer Peeyush Nandwana Jiaqiang Yan Samuel F. Evans Amy M. Elliott Chins Chinnasamy M. Parans Paranthaman |
| author_facet | Corson L. Cramer Peeyush Nandwana Jiaqiang Yan Samuel F. Evans Amy M. Elliott Chins Chinnasamy M. Parans Paranthaman |
| author_sort | Corson L. Cramer |
| collection | DOAJ |
| description | High silicon (Si) electrical steel has the potential for efficient use in applications such as electrical motors and generators with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% being achievable. The main goal of this research is to design, develop, and implement a scalable additive manufacturing process to fabricate Fe with 6.5 wt.% Si (Fe–6Si) steel with high magnetic permeability, high electrical resistivity, low coercivity, and low residual induction that other methods cannot achieve because of manufacturing limitations. Binder jet additive manufacturing was used to deposit near net shape components that were subsequently sintered via solid-state sintering to achieve near full densification. Here, it is shown that the use of solid-state sintering mitigates cracking since no rapid solidification occurs unlike fusion-based additive technologies. The Fe–6Si samples demonstrated an ultimate tensile strength of 434 MPa, electrical resistivity of 98 μΩ cm, and saturation magnetization of 1.83 T with low coercivity and high permeability. The results strongly supports to replace the only available 0.1 mm thick chemical vapor deposition (CVD) produced Si steel using the cost effective AM method with good mechanical and magnetic properties for motor applications. |
| first_indexed | 2024-12-14T10:07:23Z |
| format | Article |
| id | doaj.art-aed9d754ea334b458a8431102c7a3dce |
| institution | Directory Open Access Journal |
| issn | 2405-8440 |
| language | English |
| last_indexed | 2024-12-14T10:07:23Z |
| publishDate | 2019-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Heliyon |
| spelling | doaj.art-aed9d754ea334b458a8431102c7a3dce2022-12-21T23:07:06ZengElsevierHeliyon2405-84402019-11-01511e02804Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnetsCorson L. Cramer0Peeyush Nandwana1Jiaqiang Yan2Samuel F. Evans3Amy M. Elliott4Chins Chinnasamy5M. Parans Paranthaman6Manufacturing Demonstration Facility, Oak Ridge National Laboratory, Knoxville, TN, USA; Energy and Transportation Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USAManufacturing Demonstration Facility, Oak Ridge National Laboratory, Knoxville, TN, USA; Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USAMaterials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USAChemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USA; The Bredesen Center for Interdisciplinary Research and Graduate Education, The University of Tennessee, Knoxville, TN, 37996, USAManufacturing Demonstration Facility, Oak Ridge National Laboratory, Knoxville, TN, USA; Energy and Transportation Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USACarpenter Technology Corporation, Reading, PA, 19601, USAChemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USA; The Bredesen Center for Interdisciplinary Research and Graduate Education, The University of Tennessee, Knoxville, TN, 37996, USA; Corresponding author.High silicon (Si) electrical steel has the potential for efficient use in applications such as electrical motors and generators with cost-effective in processing, but it is difficult to manufacture. Increasing the Si content beyond 3 wt.% improves magnetic and electrical properties, with 6.5 wt.% being achievable. The main goal of this research is to design, develop, and implement a scalable additive manufacturing process to fabricate Fe with 6.5 wt.% Si (Fe–6Si) steel with high magnetic permeability, high electrical resistivity, low coercivity, and low residual induction that other methods cannot achieve because of manufacturing limitations. Binder jet additive manufacturing was used to deposit near net shape components that were subsequently sintered via solid-state sintering to achieve near full densification. Here, it is shown that the use of solid-state sintering mitigates cracking since no rapid solidification occurs unlike fusion-based additive technologies. The Fe–6Si samples demonstrated an ultimate tensile strength of 434 MPa, electrical resistivity of 98 μΩ cm, and saturation magnetization of 1.83 T with low coercivity and high permeability. The results strongly supports to replace the only available 0.1 mm thick chemical vapor deposition (CVD) produced Si steel using the cost effective AM method with good mechanical and magnetic properties for motor applications.http://www.sciencedirect.com/science/article/pii/S2405844019364643ElectromagnetismSoft magnetic alloyFe–6SiBinder jet additive manufacturingDC and AC magnetic propertiesStators |
| spellingShingle | Corson L. Cramer Peeyush Nandwana Jiaqiang Yan Samuel F. Evans Amy M. Elliott Chins Chinnasamy M. Parans Paranthaman Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets Heliyon Electromagnetism Soft magnetic alloy Fe–6Si Binder jet additive manufacturing DC and AC magnetic properties Stators |
| title | Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets |
| title_full | Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets |
| title_fullStr | Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets |
| title_full_unstemmed | Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets |
| title_short | Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets |
| title_sort | binder jet additive manufacturing method to fabricate near net shape crack free highly dense fe 6 5 wt si soft magnets |
| topic | Electromagnetism Soft magnetic alloy Fe–6Si Binder jet additive manufacturing DC and AC magnetic properties Stators |
| url | http://www.sciencedirect.com/science/article/pii/S2405844019364643 |
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