Details
| Original language | English |
|---|---|
| Article number | 100165 |
| Journal | Additive Manufacturing Letters |
| Volume | 7 |
| Early online date | 27 Jul 2023 |
| Publication status | Published - Dec 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.
Keywords
- Coils, Electric motor, Laser powder bed fusion, Multi-material, PMSM
ASJC Scopus subject areas
- Engineering(all)
- Mechanics of Materials
- Materials Science(all)
- Materials Science (miscellaneous)
- Engineering(all)
- Industrial and Manufacturing Engineering
- Engineering(all)
- Engineering (miscellaneous)
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In: Additive Manufacturing Letters, Vol. 7, 100165, 12.2023.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Multi-material laser powder bed fusion additive manufacturing of concentrated wound stator teeth
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
Y1 - 2023/12
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.
KW - Coils
KW - Electric motor
KW - Laser powder bed fusion
KW - Multi-material
KW - PMSM
UR - http://www.scopus.com/inward/record.url?scp=85166642413&partnerID=8YFLogxK
U2 - 10.1016/j.addlet.2023.100165
DO - 10.1016/j.addlet.2023.100165
M3 - Article
AN - SCOPUS:85166642413
VL - 7
JO - Additive Manufacturing Letters
JF - Additive Manufacturing Letters
M1 - 100165
ER -