Abstract
Currently, the commercial production of ferromagnetic cores involves staking thin sheets of soft magnetic material, alternating with dielectric material to reduce the eddy current losses. High silicon FeSi steels show excellent soft magnetic properties. Anyway, their workability decreases Si content increases thus imposing a technological limit in the production of thin sheets up to 3.5–4% Si. The additive manufacturing (AM) process based on laser powder bed fusion (L-PBF) offers the possibility to redesign the magnetic components, compared to conventional design, allowing to act on the chemical composition of magnetic materials and on the geometry of the components. In the case of FeSi alloys, the additive technology allows to overcome the limit of Si content opening new perspectives for the production of ferromagnetic cores with high magnetic performance. In this work the feasibility study on the production of FeSi magnetic steel components by L-PBF technology is reported. Two variants of FeSi steels, with Si content of 3.0 wt.% and 6.5 wt.%, were considered. The effect of process parameters on the densification of manufactured parts was investigated. The best operating window has been identified for both steel chemical compositions, in terms of laser scan speed and power.
Highlights
The increasing adoption of electrical components has led to realize electrical machines with increasing performances: in particular, electric motors, electric generators, electric transformers, and inductive filters are nowadays more and more required
In more detail it is worth to be mentioned that FeSi steels with Si content ranging 2 wt.% and 7 wt.%, are able to guarantee excellent electromagnetic proprieties [6] coupled a proper electrical resistivity [7]: following to that, they are commonly adopted as reference materials for ferromagnetic cores of electrical motors, generators, electrical transformers, etc. [8]
The present paper reports about the use the Direct Melting Laser Sintering (DMLS)
Summary
The increasing adoption of electrical components has led to realize electrical machines with increasing performances: in particular, electric motors, electric generators, electric transformers, and inductive filters are nowadays more and more required. In more detail it is worth to be mentioned that FeSi steels with Si content ranging 2 wt.% and 7 wt.%, are able to guarantee excellent electromagnetic proprieties [6] coupled a proper electrical resistivity [7]: following to that, they are commonly adopted as reference materials for ferromagnetic cores of electrical motors, generators, electrical transformers, etc. The commonly adopted process aimed to produce ferromagnetic is based on the superposition of FeSi thin foils coated by a dielectric material [1]: this will allow to inhibit the induced currents circulation path reducing eddy current losses [9].
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