Additive manufacturing of soft and hard magnetic materials used in electrical machines

Abstract The paper presents the evolution of electric motors from the point of view of the materials used. Magnetic materials and composite materials, which are used in the construction of electrical machines, are analysed. Composite materials based on magnetic materials have a large coercive field, a wider hysteresis cycle, they cannot be easily demagnetized and they absorb better the vibration energy - therefore the noise is reduced. In the design of electric machines, the aim is to obtain a higher magnetic permeability across the frequency spectrum and to reduce the losses in iron and copper. We analysed the radial electric motors with cylindrical magnets, electric motors in discoidal form with axial field and motors with magnets with transverse flux. Hard magnetic materials were presented and the advantage of their use was highlighted - they retain a significant residual magnetization which translates into a significant saturation magnetization. The synthesis of Fe nanoparticles is performed and the composite materials obtained from iron powders with organic or inorganic binders are analysed with the purpose of reducing iron losses in electric motors.

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Additive manufacturing and topology optimization of magnetic materials for electrical machines

Proceedings of the higher educational institutions ENERGY SECTOR PROBLEMS ◽

10.30724/1998-9903-2021-23-3-14-33 ◽

2021 ◽

Vol 23 (3) ◽

pp. 14-33

Author(s):

A. R. Safin ◽

Ranjan Kumar Behera

Keyword(s):

Topology Optimization ◽

Additive Manufacturing ◽

Magnetic Materials ◽

Permanent Magnets ◽

Electrical Machines ◽

Production Costs ◽

Comprehensive Overview ◽

Additive Production ◽

Global Trends ◽

Wide Range

THE PURPOSE. To consider the technologies for the manufacture of permanent magnets and their areas of application. To identify global trends in the change in demand for rare earth metals. To study the prospects for the development of additive production of polymer magnetic materials. METHODS. When studying this issue, an analysis of a wide range of domestic and foreign sources of scientific literature was used. RESULTS. Prospective technologies for the additive production of polymer magnetic materials for a variety of applications have been studied. The need to establish a relationship between the properties of the starting material, the diameters of the extrusion nozzles, the printing parameters, as well as the mechanical and functional properties of the resulting magnets is indicated. CONCLUSION. This article provides a comprehensive overview of recent advances in the application of additive manufacturing, topology optimization and their integration for electrical machines and their magnetic components. Additive manufacturing technologies such as 3D printing, BAAM - the technology has potential advantages such as lower production costs, elimination of the need to make molds, the ability to create permanent magnets with field profiles and magnetic properties that cannot be obtained using modern methods. The considered technologies can be used as a tool in the design and development of innovative magnets for electric motors, which will make the most of the magnetic flux and thereby increase the energy efficiency of drive systems. This will allow rapid prototyping of parts and reduce the time to market for new products.

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Characteristics comparison and selection guide for magnetic materials used in electrical machines

2015 IEEE International Electric Machines & Drives Conference (IEMDC) ◽

10.1109/iemdc.2015.7409206 ◽

2015 ◽

Cited By ~ 7

Author(s):

Andreas Krings ◽

Marco Cossale ◽

Alberto Tenconi ◽

Juliette Soulard ◽

Andrea Cavagnino ◽

...

Keyword(s):

Magnetic Materials ◽

Electrical Machines ◽

Materials Used

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A Review on Additive Manufacturing Possibilities for Electrical Machines

Energies ◽

10.3390/en14071940 ◽

2021 ◽

Vol 14 (7) ◽

pp. 1940

Author(s):

Muhammad Usman Naseer ◽

Ants Kallaste ◽

Bilal Asad ◽

Toomas Vaimann ◽

Anton Rassõlkin

Keyword(s):

Additive Manufacturing ◽

Large Scale ◽

Three Dimensional ◽

Electrical Machines ◽

Electromagnetic Properties ◽

Scale Production ◽

Performance Parameters ◽

Large Scale Production ◽

One Step ◽

Manufacturing Techniques

This paper presents current research trends and prospects of utilizing additive manufacturing (AM) techniques to manufacture electrical machines. Modern-day machine applications require extraordinary performance parameters such as high power-density, integrated functionalities, improved thermal, mechanical & electromagnetic properties. AM offers a higher degree of design flexibility to achieve these performance parameters, which is impossible to realize through conventional manufacturing techniques. AM has a lot to offer in every aspect of machine fabrication, such that from size/weight reduction to the realization of complex geometric designs. However, some practical limitations of existing AM techniques restrict their utilization in large scale production industry. The introduction of three-dimensional asymmetry in machine design is an aspect that can be exploited most with the prevalent level of research in AM. In order to take one step further towards the enablement of large-scale production of AM-built electrical machines, this paper also discusses some machine types which can best utilize existing developments in the field of AM.

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Additive Manufacturing Under Lunar Gravity and Microgravity

Microgravity Science and Technology ◽

10.1007/s12217-021-09878-4 ◽

2021 ◽

Vol 33 (2) ◽

Author(s):

B. Reitz ◽

C. Lotz ◽

N. Gerdes ◽

S. Linke ◽

E. Olsen ◽

...

Keyword(s):

Additive Manufacturing ◽

Spare Parts ◽

Manufacturing Processes ◽

Complex Structures ◽

Lunar Gravity ◽

Limited Extent ◽

Test Environment ◽

Manufacturing Tests ◽

Laser Experiments ◽

Materials Used

AbstractMankind is setting to colonize space, for which the manufacturing of habitats, tools, spare parts and other infrastructure is required. Commercial manufacturing processes are already well engineered under standard conditions on Earth, which means under Earth’s gravity and atmosphere. Based on the literature review, additive manufacturing under lunar and other space gravitational conditions have only been researched to a very limited extent. Especially, additive manufacturing offers many advantages, as it can produce complex structures while saving resources. The materials used do not have to be taken along on the mission, they can even be mined and processed on-site. The Einstein-Elevator offers a unique test environment for experiments under different gravitational conditions. Laser experiments on selectively melting regolith simulant are successfully conducted under lunar gravity and microgravity. The created samples are characterized in terms of their geometry, mass and porosity. These experiments are the first additive manufacturing tests under lunar gravity worldwide.

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Effect of the Temperature on the Magnetic and Energetic Properties of Soft Magnetic Composite Materials

Energies ◽

10.3390/en14154400 ◽

2021 ◽

Vol 14 (15) ◽

pp. 4400

Author(s):

Luca Ferraris ◽

Fausto Franchini ◽

Emir Pošković ◽

Marco Actis Grande ◽

Róbert Bidulský

Keyword(s):

Magnetic Materials ◽

Eddy Currents ◽

Electrical Machines ◽

Soft Magnetic Materials ◽

Magnetic Composite ◽

Soft Magnetic ◽

Soft Magnetic Composite ◽

Magnetic Performance ◽

Magnetic Circuits ◽

Energetic Characterization

In recent years, innovative magnetic materials have been introduced in the field of electrical machines. In the ambit of soft magnetic materials, laminated steels guarantee good robustness and high magnetic performance but, in some high-frequency applications, can be replaced by Soft Magnetic Composite (SMC) materials. SMC materials allow us to reduce the eddy currents and to design innovative 3D magnetic circuits. In general, SMCs are characterized at room temperature, but as electrical machines operate at high temperature (around 100 °C), an investigation analysis of the temperature effect has been carried out on these materials; in particular, three SMC samples with different binder percentages and process parameters have been considered for magnetic and energetic characterization.

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