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Additive manufacturing of soft magnetic materials and components

Wednesday (26.09.2018)
17:00 - 17:15 S1/03 - 221
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The limitation of electrical steel in respect to minimum sheet thickness and maximum silicon content requires new material and process innovations in particular for high-speed traction motor applications in electric cars. New opportunities are offered by favorable material compositions like FeSi6.5 with larger electrical resistivity and zero magneto¬striction. However, this material shows limited rollability due to the increased brittleness. Here, additive manufacturing technologies like selective laser melting (SLM), based on laser powder bed fusion (LPBF), enables novel topological and layered structures or combinations thereof for tailored properties of efficient energy converters. In this work, the influence of manufacturing parameters like laser power, laser scan velocity and volume energy density on the microstructure and related magnetic properties and losses are studied. For high-silicon electrical steel (FeSi6.5) the potential of the concept is demonstrated and compared to conventional electrical steel and soft magnetic composites. For additive manufacturing, both commercial equipment and an automated process chamber, developed for lab scale experimentation, have been used. The lab scale chamber enables usage of small powder amounts and high flexibility in the fabrication of different materials of optimized magnetic and electric properties.

David Schuller
Aalen University of Applied Sciences - Technology and Economics
Additional Authors:
  • Torsten Kunert
    Aalen University
  • Julian Schurr
    Aalen University
  • Tim Schubert
    Aalen University
  • Dr. Timo Bernthaler
    Aalen University
  • Prof. Dr. Harald Riegel
    Laser Application Center (LAZ)
  • Prof. Dr. Dagmar Goll
    Aalen University
  • Prof. Dr. Gerhard Schneider
    Aalen University