An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor
Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si material...
Saved in:
| Main Authors: | , , , , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-02-01
|
| Series: | Applied Sciences |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2076-3417/15/4/1706 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1849723382119006208 |
|---|---|
| author | Tej N. Lamichhane Haobo Wang Chins Chinnasamy Latha Sethuraman Fred A. List Peeyush Nandwana Jiaqiang Yan Zheng Gai Mariappan Parans Paranthaman |
| author_facet | Tej N. Lamichhane Haobo Wang Chins Chinnasamy Latha Sethuraman Fred A. List Peeyush Nandwana Jiaqiang Yan Zheng Gai Mariappan Parans Paranthaman |
| author_sort | Tej N. Lamichhane |
| collection | DOAJ |
| description | Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd<sub>2</sub>Fe<sub>14</sub>B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices. |
| format | Article |
| id | doaj-art-5c8f4b53e8a049e3bf4d416d9aa20b04 |
| institution | DOAJ |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-5c8f4b53e8a049e3bf4d416d9aa20b042025-08-20T03:11:03ZengMDPI AGApplied Sciences2076-34172025-02-01154170610.3390/app15041706An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical MotorTej N. Lamichhane0Haobo Wang1Chins Chinnasamy2Latha Sethuraman3Fred A. List4Peeyush Nandwana5Jiaqiang Yan6Zheng Gai7Mariappan Parans Paranthaman8Oak Ridge National Laboratory, Chemical Sciences Division, Oak Ridge, TN 37831, USAOak Ridge National Laboratory, Chemical Sciences Division, Oak Ridge, TN 37831, USACarpenter Technology Corporation, Reading, PA 19601, USANational Renewable Energy Laboratory, National Wind Technology Center, Golden, CO 80401, USAOak Ridge National Laboratory, Manufacturing Science Division, Oak Ridge, TN 37831, USANational Renewable Energy Laboratory, National Wind Technology Center, Golden, CO 80401, USAOak Ridge National Laboratory, Materials Science and Technology Division, Oak Ridge, TN 37831, USAOak Ridge National Laboratory, Center for Nanophase Materials Sciences, Oak Ridge, TN 37831, USAOak Ridge National Laboratory, Chemical Sciences Division, Oak Ridge, TN 37831, USAAdditive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd<sub>2</sub>Fe<sub>14</sub>B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices.https://www.mdpi.com/2076-3417/15/4/1706soft magnetic materialsFe-3 wt.% Siselective laser meltingBAAM isotropic NdFeB PPS bonded magnetselectrical motorsback EMF |
| spellingShingle | Tej N. Lamichhane Haobo Wang Chins Chinnasamy Latha Sethuraman Fred A. List Peeyush Nandwana Jiaqiang Yan Zheng Gai Mariappan Parans Paranthaman An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor Applied Sciences soft magnetic materials Fe-3 wt.% Si selective laser melting BAAM isotropic NdFeB PPS bonded magnets electrical motors back EMF |
| title | An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor |
| title_full | An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor |
| title_fullStr | An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor |
| title_full_unstemmed | An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor |
| title_short | An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor |
| title_sort | additively manufactured fe 3si stator for a high performance electrical motor |
| topic | soft magnetic materials Fe-3 wt.% Si selective laser melting BAAM isotropic NdFeB PPS bonded magnets electrical motors back EMF |
| url | https://www.mdpi.com/2076-3417/15/4/1706 |
| work_keys_str_mv | AT tejnlamichhane anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT haobowang anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT chinschinnasamy anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT lathasethuraman anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT fredalist anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT peeyushnandwana anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT jiaqiangyan anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT zhenggai anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT mariappanparansparanthaman anadditivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT tejnlamichhane additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT haobowang additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT chinschinnasamy additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT lathasethuraman additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT fredalist additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT peeyushnandwana additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT jiaqiangyan additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT zhenggai additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor AT mariappanparansparanthaman additivelymanufacturedfe3sistatorforahighperformanceelectricalmotor |