3D Printing of Magnetic Cores for Electrical Motors
Abstract
Research Problem:Technological advancements have been made in 3D printing plastics and many metals, promoting its use for production of quality parts with functional mechanical properties. In spite of these advances, there is still a critical gap in the knowledge base that pertains to the functional and structural characteristics of deposited iron alloys for the design of magnetic cores in electric motors, transformers and other magnetic assemblies. Availability of practical additive manufacturing techniques that provide acceptable electrical, magnetic and mechanical properties for the magnetic core will accelerate the development of power dense and efficient 3D printed electric motors and generators.Objective:The overall objective of the proposed research is to develop magnetic cores using additive manufacturing technology via the investigation of the materials magnetic properties.Technical Approaches:The proposed research applies an iterative learning process to advance the knowledge of the interrelationships among material composition, process parameters, microstructure, functional properties and performance of the magnetic core of an electric motor. Thorough electrical, magnetic and microstructural characterization will be used to define the relationship across material composition, process parameters, microstructure and functional properties of 3D printed iron alloys. A 3D printed magnetic core with optimal electrical and magnetic properties will be accomplished through parametric sensitivity analysis and multi-objective genetic algorithms.Anticipated outcome of successful research:To date, there have been limitations in the conventional processes used to manufacture the magnetic core of an electric motor. The creative, original, and transformative research proposed here is focused on exploiting the benefits of additive manufacturing process in the design of the magnetic core. At the completion of this program, we will have developed binder-jet and sintering processes for printing magnetic cores with characteristics desirable for efficient energy conversion. The proposed research is expected to contribute a markedly improved magnetic core that plays a key role in electromechanical energy conversion of electric motors and generators. This contribution is significant because it is expected to provide a broad knowledge base and adequate tools for designing electric machines that capitalize on the benefits of additive manufacturing without sacrificing performance.Impact on DoD capabilities:On the roadmap to an electric naval force, motors play a key role in increasing mobility, stealth, endurance and fuel efficiency. Motors are designed to operate most efficiently at a certain torque and speed requiring many different motors onboard for the various systems. Deploying naval ships with spare motors and generators may not be feasible and getting parts to ships at sea is also a challenge. 3D printing can potentially eliminate the logistical nightmares of maintenance and replacing electric motors and generators on deployed naval ships. Thus, the outcomes of this proposed project are not only expected to fundamentally advance the fields of additive manufacturing and energy conversion, but also have a simultaneous impact on the capabilities of crews at sea to maintain safe ship operation.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jul 26, 2018
- Source ID
- N000141812514
Entities
People
- Shanelle N. Foster
Organizations
- Michigan State University
- Office of Naval Research
- United States Navy