AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines

Hans Tiismus, Ants Kallaste, Anouar Belahcen, Marek Tarraste, Toomas Vaimann, Anton Rassõlkin, Bilal Asad 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
Marek Tarraste: Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 19086 Tallinn, Estonia
Toomas Vaimann: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Anton Rassõlkin: Institute of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, 19086 Tallinn, Estonia
Bilal Asad: 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 5, 1-13

Abstract: Additively manufactured soft magnetic Fe-3.7%w.t.Si toroidal samples with solid and novel partitioned cross-sectional geometries are characterized through magnetic measurements. This study focuses on the effect of air gaps and annealing temperature on AC core losses at the 50 Hz frequency. In addition, DC electromagnetic material properties are presented, showing comparable results to conventional and other 3D-printed, high-grade, soft magnetic materials. The magnetization of 1.5 T was achieved at 1800 A/m, exhibiting a maximum relative permeability of 28,900 and hysteresis losses of 0.61 (1 T) and 1.7 (1.5 T) W/kg. A clear trend of total core loss reduction at 50 Hz was observed in relation to the segregation of the specimen cross-sectional topology. The lowest 50 Hz total core losses were measured for the toroidal specimen with four internal air gaps annealed at 1200 °C, exhibiting a total core loss of 1.2 (1 T) and 5.5 (1.5 T) W/kg. This is equal to an 860% total core loss reduction at 1 T and a 510% loss reduction at 1.5 T magnetization compared to solid bulk-printed material. Based on the findings, the advantages and disadvantages of printed air-gapped material internal structures are discussed in detail.

Keywords: electric machines; additive manufacturing; soft magnetic materials; selective laser melting; iron losses; magnetic properties (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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