Additive Manufacturing and Performance of E-Type Transformer Core

Hans Tiismus, Ants Kallaste, Anouar Belahcen, Anton Rassolkin, Toomas Vaimann and Payam Shams Ghahfarokhi
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Hans Tiismus: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Ants Kallaste: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Anouar Belahcen: Department of Electrical Engineering and Automation, Aalto University, 02150 Espoo, Finland
Anton Rassolkin: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Toomas Vaimann: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Payam Shams Ghahfarokhi: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia

Energies, 2021, vol. 14, issue 11, 1-14

Abstract: Additive manufacturing of ferromagnetic materials for electrical machine applications is maturing. In this work, a full E-type transformer core is printed, characterized, and compared in terms of performance with a conventional Goss textured core. For facilitating a modular winding and eddy current loss reduction, the 3D printed core is assembled from four novel interlocking components, which structurally imitate the E-type core laminations. Both cores are compared at approximately their respective optimal working conditions, at identical magnetizing currents. Due to the superior magnetic properties of the Goss sheet conventional transformer core, 10% reduced efficiency (from 80.5% to 70.1%) and 34% lower power density (from 59 VA/kg to 39 VA/kg) of the printed transformer are identified at operating temperature. The first prototype transformer core demonstrates the state of the art and initial optimization step for further development of additively manufactured soft ferromagnetic components. Further optimization of both the 3D printed material and core design are proposed for obtaining higher electrical performance for AC applications.

Keywords: additive manufacturing; soft magnetic materials; selective laser melting; iron losses; magnetic properties; transformer (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2021
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (3)

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