Hysteresis Measurements and Numerical Losses Segregation of Additively Manufactured Silicon Steel for 3D Printing Electrical Machines

Samples from FeSi4 powder were fabricated with a low power selective laser melting (SLM) system using a laser re-melting strategy. The sample material was characterized through magnetic measurements. The study showed excellent DC magnetic properties, comparable to commercial and other 3D printed soft ferromagnetic materials from the literature at low (1 T) magnetization. Empirical total core losses were segregated into hysteresis, eddy and excessive losses via the subtraction of finite element method (FEM) simulated eddy current losses and hysteresis losses measured at quasi-static conditions. Hysteresis losses were found to decrease from 3.65 to 0.95 W/kg (1 T, 50 Hz) after the annealing. Both empirical and FEM results confirm considerable eddy currents generated in the printed bulk toroidal sample, which increase dramatically at high material saturation after annealing. These losses could potentially be reduced by using partitioned material internal structure realized by printed airgaps. Similarly, with regard to the samples characterized in this study, the substantially increased core losses induced by material oversaturation due to reduced filling factor may present a challenge in realizing 3D printed electrical machines with comparable performance to established 2D laminated designs.

A thermal extension and loss model for Tellinen’s hysteresis model

Purpose The thermally extended Tellinen model (Kühn et al., to appear) is here investigated and equipped with a hysteresis loss model, while preserving its simple structure. Design/methodology/approach As in the original model, these approaches are based upon phenomenal observations and measured saturation curves. The authors start with the original model and step-by-step add their extensions, such that in the end they can apply the extended model in a finite element method (FEM) simulation. During the process, care is taken to ensure that the applicability in a FEM simulation is not impaired, in terms of memory requirements and computing power. Findings In comparison to the original model, this extended model needs some further requirements and so is a little bit more limited in its application. It is in itself coherent and well defined. The authors provide an on-the-fly algorithm computation of hysteresis losses. First numerical results for a coupled field/thermal system show expected behavior. Originality/value The original model (Tellinen, 1998) does not take temperature into account. It includes a model for calculating hysteresis losses, but it differs largely from the approach presented here. The thermal extension is now also equipped with an on-the-fly method for hysteresis losses. Furthermore, the authors provide some analysis of simple, stable loops.