Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications

Hans Tiismus, Ants Kallaste, Toomas Vaimann, Liina Lind, Indrek Virro, Anton Rassõlkin and Tatjana Dedova
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Hans Tiismus: Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
Ants Kallaste: Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
Toomas Vaimann: Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
Liina Lind: Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
Indrek Virro: Institute of Forestry and Engineering, Estonian University of Life Sciences, Fr. R. Kreutzwaldi 1, 51006 Tartu, Estonia
Anton Rassõlkin: Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia
Tatjana Dedova: Department of Materials Science, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia

Energies, 2022, vol. 15, issue 10, 1-26

Abstract: Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by the electrical machine (EM) research community to develop and integrate novel additive components. Several challenges remain, however, in printing soft magnetic flux guides—most prominently, reducing the induced eddy currents to achieve competitive AM core efficiency. This paper demonstrates the workflow of laser additive manufacturing magnetic cores with superior magnetic properties to soft magnetic composites (at 50 Hz excitation): describing the workflow, parameter tuning for both printing and annealing, and shape optimization. Process optimization yielded the optimal energy density of 77 J/mm 3 and annealing temperature of 1200 °C, applied to prepare the samples with the highest relative density (99.86%), lowest surface roughness R z (0.041 mm), minimal hysteresis losses (0.8 W/kg at 1.0 T, 50 Hz), and ultimate yield strength of 420 MPa. For Eddy current suppression, the sample (5 × 5 × 60 mm toroid) with bi-directional grading reached specific core losses as low as 1.8 W/kg (W 10,50 ). Based on the findings, the advantages and disadvantages of AM graded cores are discussed in detail.

Keywords: additive manufacturing; electrical machines; soft magnetic materials; hysteresis loss; eddy current loss; annealing; selective laser melting (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: 2022
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