Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth

Publikation: Beitrag in FachzeitschriftArtikelForschungPeer-Review

Autoren

  • Marcus Oel
  • Johannes Rossmann
  • Behrend Bode
  • Ina Meyer
  • Tobias Ehlers
  • Christoph M. Hackl
  • Roland Lachmayer

Externe Organisationen

  • Hochschule für angewandte Wissenschaften München
Forschungs-netzwerk anzeigen

Details

OriginalspracheEnglisch
Aufsatznummer100165
FachzeitschriftAdditive Manufacturing Letters
Jahrgang7
Frühes Online-Datum27 Juli 2023
PublikationsstatusVeröffentlicht - Dez. 2023

Abstract

Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites.

ASJC Scopus Sachgebiete

Zitieren

Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth. / Oel, Marcus; Rossmann, Johannes; Bode, Behrend et al.
in: Additive Manufacturing Letters, Jahrgang 7, 100165, 12.2023.

Publikation: Beitrag in FachzeitschriftArtikelForschungPeer-Review

Oel, M, Rossmann, J, Bode, B, Meyer, I, Ehlers, T, Hackl, CM & Lachmayer, R 2023, 'Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth', Additive Manufacturing Letters, Jg. 7, 100165. https://doi.org/10.1016/j.addlet.2023.100165
Oel, M., Rossmann, J., Bode, B., Meyer, I., Ehlers, T., Hackl, C. M., & Lachmayer, R. (2023). Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth. Additive Manufacturing Letters, 7, Artikel 100165. https://doi.org/10.1016/j.addlet.2023.100165
Oel M, Rossmann J, Bode B, Meyer I, Ehlers T, Hackl CM et al. Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth. Additive Manufacturing Letters. 2023 Dez;7:100165. Epub 2023 Jul 27. doi: 10.1016/j.addlet.2023.100165
Oel, Marcus ; Rossmann, Johannes ; Bode, Behrend et al. / Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth. in: Additive Manufacturing Letters. 2023 ; Jahrgang 7.
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abstract = "Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites.",
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AU - Oel, Marcus

AU - Rossmann, Johannes

AU - Bode, Behrend

AU - Meyer, Ina

AU - Ehlers, Tobias

AU - Hackl, Christoph M.

AU - Lachmayer, Roland

N1 - Funding Information: The project “Major Research Instrumentation for integration of efficient effects in multi-material structural components” was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - Project number 445707542. The project “Computer tomograph for optomechatronic systems” was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - Project number 432176896. The authors are deeply indebted to Prof. Dr.-Ing. Frank Krafft, and Sebastien Baur and Florian Proebstl of HM Munich University of Applied Sciences, who provided the equipment for and carried out the heat treatment of the coils and preliminary electric measurements, respectively.”

PY - 2023/12

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N2 - Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites.

AB - Additive manufacturing using Powder Bed Fusion by Laser Beam (PBF-LB) enables products with high design freedom. In addition, the ability to process more than one material in all three spatial directions makes it possible to produce highly functional components in one single process. This article investigates whether multi-material manufacturing using PBF-LB is suitable for producing coils for electric motors, which are designed with integrated cooling channels to increase the power density. For this purpose, the copper alloy CuCr1Zr for the coils and the stainless steel 1.4404 (316L) for the core are processed simultaneously. The component designs were verified using 2D and 3D finite element analysis and then manufactured in a multi-material PBF-LB process. While good electrical conductivity of the copper alloy was achieved by heat treatment, it was found that thermal distortion caused deviations from the nominal geometry. The measurement of the electrical properties showed that this distortion leads to short-circuit currents within the coils and the teeth. On this basis, ideas for solutions were developed, with the help of which the functionality of the coils can be ensured or the power density can also be increased. In addition to adapting the design of the component, this includes processing additional or other materials, such as soft magnetic composites.

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