Topology optimized soft magnetic cores by laser powder bed fusion

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    Abstract

    Additive manufacturing (AM) technologies have opened up new possibilities for realizing magnetic circuit designs, ultimately leading to electrical machines with enhanced performance, lower material consumption and cost. This study introduces laser powder bed fusion (L-PBF) manufacturing of topology optimized soft magnetic cores. As a first step of optimization, we investigate perforated core structures with gaps the purpose of which is to decrease the losses. Processing route starting from powder production of soft magnetic Fe-49Co-2V material, followed by process parameter optimization for L-PBF and finally the effect of heat treatment on the magnetic properties are shown. Effect of structural choices on the core losses of the soft magnetic components is studied. Based on the magnetic measurements, the best heat-treatment cycle led to magnetic saturation, permeability and coercivity comparable to commercial standardized Fe-49Co-2V alloy. Magnetic measurement results of perforated test samples show that eddy current losses can be significantly reduced with small structural modifications. Finite element computations performed support this conclusion.
    Original languageEnglish
    Title of host publicationEuro PM2019 Congress Proceedings
    PublisherEuropean Powder Metallurgy Association (EPMA)
    Number of pages10
    EditionUSB
    ISBN (Electronic)978-1-899072-51-4
    Publication statusPublished - 2019
    MoE publication typeB3 Non-refereed article in conference proceedings
    EventEuro PM2019 Congress & Exhibition: Europe's annual powder metallurgy congress and exhibition - Maastricht, Netherlands
    Duration: 13 Oct 201916 Oct 2019

    Conference

    ConferenceEuro PM2019 Congress & Exhibition
    Country/TerritoryNetherlands
    CityMaastricht
    Period13/10/1916/10/19

    Keywords

    • Soft magnetic material
    • Fe-49Co-2V
    • additive manufacturing (AM)
    • topology optimization
    • L-PBF
    • Magnetic properties

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