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

Tiismus, Hans; Kallaste, Ants; Vaimann, Toomas; Lind, Liina; Virro, Indrek; Rassõlkin, Anton; Dedova, Tatjana

doi:10.3390/en15103665

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

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Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia

Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia

Institute of Forestry and Engineering, Estonian University of Life Sciences, Fr. R. Kreutzwaldi 1, 51006 Tartu, Estonia

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Department of Materials Science, Tallinn University of Technology, Ehitajate tee 5, 19086 Tallinn, Estonia

Author to whom correspondence should be addressed.

Academic Editors: João Filipe Pereira Fernandes and Silvio Vaschetto

Energies 2022, 15(10), 3665; https://doi.org/10.3390/en15103665

Received: 25 April 2022 / Revised: 10 May 2022 / Accepted: 13 May 2022 / Published: 17 May 2022

(This article belongs to the Special Issue Advanced Manufacturing and Materials for Next Generation Electrical Machines)

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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/mm³ 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. View Full-Text

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

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MDPI and ACS Style

Tiismus, H.; Kallaste, A.; Vaimann, T.; Lind, L.; Virro, I.; Rassõlkin, A.; Dedova, T. Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications. Energies 2022, 15, 3665. https://doi.org/10.3390/en15103665

AMA Style

Tiismus H, Kallaste A, Vaimann T, Lind L, Virro I, Rassõlkin A, Dedova T. Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications. Energies. 2022; 15(10):3665. https://doi.org/10.3390/en15103665

Chicago/Turabian Style

Tiismus, Hans, Ants Kallaste, Toomas Vaimann, Liina Lind, Indrek Virro, Anton Rassõlkin, and Tatjana Dedova. 2022. "Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications" Energies 15, no. 10: 3665. https://doi.org/10.3390/en15103665

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