Topology optimized soft magnetic cores by laser powder bed fusion

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientific

    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 Power 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 - Maastricht, Netherlands
    Duration: 13 Oct 201916 Oct 2019

    Conference

    ConferenceEuro PM2019 Congress & Exhibition
    CountryNetherlands
    CityMaastricht
    Period13/10/1916/10/19

    Fingerprint

    Magnetic cores
    Fusion reactions
    Magnetic variables measurement
    Topology
    Powders
    Lasers
    3D printers
    Heat treatment
    Magnetic circuits
    Saturation magnetization
    Eddy currents
    Coercive force
    Magnetic properties
    Processing
    Costs

    Keywords

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

    Cite this

    @inproceedings{dc70e263fc1046e8bdef999a18c48cbc,
    title = "Topology optimized soft magnetic cores by laser powder bed fusion",
    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.",
    keywords = "Soft magnetic material, Fe-49Co-2V, additive manufacturing (AM), topology optimization, L-PBF, Magnetic properties",
    author = "Tuomas Riipinen and Jenni Pippuri-M{\"a}kel{\"a}inen and Tomi Lindroos and Sini Mets{\"a}-Kortelainen and Janne Ker{\"a}nen and Aino Manninen",
    year = "2019",
    language = "English",
    booktitle = "Euro PM2019 Congress Proceedings",
    publisher = "European Power Metallurgy Association EPMA",
    edition = "USB",

    }

    Riipinen, T, Pippuri-Mäkeläinen, J, Lindroos, T, Metsä-Kortelainen, S, Keränen, J & Manninen, A 2019, Topology optimized soft magnetic cores by laser powder bed fusion. in Euro PM2019 Congress Proceedings. USB edn, European Power Metallurgy Association EPMA, Euro PM2019 Congress & Exhibition, Maastricht, Netherlands, 13/10/19.

    Topology optimized soft magnetic cores by laser powder bed fusion. / Riipinen, Tuomas; Pippuri-Mäkeläinen, Jenni; Lindroos, Tomi; Metsä-Kortelainen, Sini; Keränen, Janne; Manninen, Aino.

    Euro PM2019 Congress Proceedings. USB. ed. European Power Metallurgy Association EPMA, 2019.

    Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientific

    TY - GEN

    T1 - Topology optimized soft magnetic cores by laser powder bed fusion

    AU - Riipinen, Tuomas

    AU - Pippuri-Mäkeläinen, Jenni

    AU - Lindroos, Tomi

    AU - Metsä-Kortelainen, Sini

    AU - Keränen, Janne

    AU - Manninen, Aino

    PY - 2019

    Y1 - 2019

    N2 - 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.

    AB - 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.

    KW - Soft magnetic material

    KW - Fe-49Co-2V

    KW - additive manufacturing (AM)

    KW - topology optimization

    KW - L-PBF

    KW - Magnetic properties

    M3 - Conference article in proceedings

    BT - Euro PM2019 Congress Proceedings

    PB - European Power Metallurgy Association EPMA

    ER -