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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Hans Tiismus & Ants Kallaste & Anouar Belahcen & Marek Tarraste & Toomas Vaimann & Anton Rassõlkin & Bilal Asad & Payam Shams Ghahfarokhi, 2021. "AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines," Energies, MDPI, vol. 14(5), pages 1-13, February.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:5:p:1241-:d:505129
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    References listed on IDEAS

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    1. Jafari, Davoud & Wits, Wessel W., 2018. "The utilization of selective laser melting technology on heat transfer devices for thermal energy conversion applications: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 91(C), pages 420-442.
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    Cited by:

    1. Daniele Michieletto & Luigi Alberti & Filippo Zanini & Simone Carmignato, 2024. "Electromagnetic Characterization of Silicon–Iron Additively Manufactured Cores for Electric Machines," Energies, MDPI, vol. 17(3), pages 1-13, January.
    2. Hans Tiismus & Ants Kallaste & Anouar Belahcen & Anton Rassolkin & Toomas Vaimann & Payam Shams Ghahfarokhi, 2021. "Additive Manufacturing and Performance of E-Type Transformer Core," Energies, MDPI, vol. 14(11), pages 1-14, June.
    3. Toomas Vaimann & Ants Kallaste, 2023. "Additive Manufacturing of Electrical Machines—Towards the Industrial Use of a Novel Technology," Energies, MDPI, vol. 16(1), pages 1-10, January.

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