Hysteresis Measurements and Numerical Losses Segregation of Additively Manufactured Silicon Steel for 3D Printing Electrical Machines

Samples from FeSi4 powder were fabricated with a low power selective laser melting (SLM) system using a laser re-melting strategy. The sample material was characterized through magnetic measurements. The study showed excellent DC magnetic properties, comparable to commercial and other 3D printed sof...

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Bibliographic Details
Published in:Applied sciences 2020-09, Vol.10 (18), p.6515
Main Authors: Tiismus, Hans, Kallaste, Ants, Belahcen, Anouar, Vaimann, Toomas, Rassõlkin, Anton, Lukichev, Dmitry
Format: Article
Language:English
Subjects:
3-D printers
Additive manufacturing
Annealing
Carbon
Core loss
Current loss
Eddy currents
Efficiency
electric machines
FEM
Ferromagnetic materials
Finite element method
Hysteresis
iron losses
Laser beam melting
Lasers
Magnetic measurement
Magnetic properties
Particle size
R&D
Research & development
Scanning electron microscopy
selective laser melting
soft magnetic materials
Spectrum analysis
Subtraction
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Summary:Samples from FeSi4 powder were fabricated with a low power selective laser melting (SLM) system using a laser re-melting strategy. The sample material was characterized through magnetic measurements. The study showed excellent DC magnetic properties, comparable to commercial and other 3D printed soft ferromagnetic materials from the literature at low (1 T) magnetization. Empirical total core losses were segregated into hysteresis, eddy and excessive losses via the subtraction of finite element method (FEM) simulated eddy current losses and hysteresis losses measured at quasi-static conditions. Hysteresis losses were found to decrease from 3.65 to 0.95 W/kg (1 T, 50 Hz) after the annealing. Both empirical and FEM results confirm considerable eddy currents generated in the printed bulk toroidal sample, which increase dramatically at high material saturation after annealing. These losses could potentially be reduced by using partitioned material internal structure realized by printed airgaps. Similarly, with regard to the samples characterized in this study, the substantially increased core losses induced by material oversaturation due to reduced filling factor may present a challenge in realizing 3D printed electrical machines with comparable performance to established 2D laminated designs.
ISSN:2076-3417
2076-3417
DOI:10.3390/app10186515