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Title: Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si

Abstract

The influence of geometry and scan pattern on the microstructure evolution and magnetic performance of additively manufactured Fe-3Si components was investigated. To reduce eddy current losses, novel geometries were designed and built and the microstructure and properties of these samples were characterized. The laser scan pattern was shown to strongly influence both the as-built grain structure and strength of the crystallographic texture, resulting in measurable changes in the as-built magnetic performance. In thin wall samples, heat treatment resulted in an increase in the maximum relative magnetic permeability and decrease in power losses in most samples, consistent with grain growth. However, decreases in the spacing between thin walls to increase the stacking factor of the cross-section was shown to result in unwanted electrical shorting between walls and an increase in eddy current losses. Compared to simple parallel plate construction and a mesh structure, a novel cross-section design based on the Hilbert space filling curve was found to produce the lowest power losses. The mechanisms behind these results were explored using a combination of heat conduction and electromagnetic simulations, providing a route for future component and process optimization.

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [1]; ORCiD logo [1];  [1]; ORCiD logo [1]; ORCiD logo [1]
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  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division, and Manufacturing Demonstration Facility
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Electrical & Electronic Systems Division
Publication Date:
Research Org.:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Electricity (OE)
OSTI Identifier:
1559675
Alternate Identifier(s):
OSTI ID: 1877294
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 29; Journal Issue: C; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Selective laser melting; Fe-Si; Microstructure; Soft-magnets; Magnetic characterization

Citation Formats

Plotkowski, Alex, Pries, Jason, List III, Fred, Nandwana, Peeyush, Stump, Benjamin, Carver, Keith, and Dehoff, Ryan. Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si. United States: N. p., 2019. Web. doi:10.1016/j.addma.2019.100781.
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Plotkowski, Alex, Pries, Jason, List III, Fred, Nandwana, Peeyush, Stump, Benjamin, Carver, Keith, & Dehoff, Ryan. Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si. United States. https://doi.org/10.1016/j.addma.2019.100781
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Plotkowski, Alex, Pries, Jason, List III, Fred, Nandwana, Peeyush, Stump, Benjamin, Carver, Keith, and Dehoff, Ryan. Wed . "Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si". United States. https://doi.org/10.1016/j.addma.2019.100781. https://www.osti.gov/servlets/purl/1559675.
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@article{osti_1559675,
title = {Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si},
author = {Plotkowski, Alex and Pries, Jason and List III, Fred and Nandwana, Peeyush and Stump, Benjamin and Carver, Keith and Dehoff, Ryan},
abstractNote = {The influence of geometry and scan pattern on the microstructure evolution and magnetic performance of additively manufactured Fe-3Si components was investigated. To reduce eddy current losses, novel geometries were designed and built and the microstructure and properties of these samples were characterized. The laser scan pattern was shown to strongly influence both the as-built grain structure and strength of the crystallographic texture, resulting in measurable changes in the as-built magnetic performance. In thin wall samples, heat treatment resulted in an increase in the maximum relative magnetic permeability and decrease in power losses in most samples, consistent with grain growth. However, decreases in the spacing between thin walls to increase the stacking factor of the cross-section was shown to result in unwanted electrical shorting between walls and an increase in eddy current losses. Compared to simple parallel plate construction and a mesh structure, a novel cross-section design based on the Hilbert space filling curve was found to produce the lowest power losses. The mechanisms behind these results were explored using a combination of heat conduction and electromagnetic simulations, providing a route for future component and process optimization.},
doi = {10.1016/j.addma.2019.100781},
journal = {Additive Manufacturing},
number = C,
volume = 29,
place = {United States},
year = {Wed Jul 03 00:00:00 EDT 2019},
month = {Wed Jul 03 00:00:00 EDT 2019}
}
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Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1016/j.addma.2019.100781
Copyright Statement
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Citation Metrics:
Cited by: 37 works
Citation information provided by
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Figures / Tables:

Table 1 Table 1: Nominal process parameters used to build the Fe-3Si.
All figures and tables (18 total)
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Works referenced in this record:

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  • Progress in Additive Manufacturing, Vol. 4, Issue 4
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    Works referencing / citing this record:

    Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review
    journal, January 2021

    • Pham, Thang; Kwon, Patrick; Foster, Shanelle
    • Energies, Vol. 14, Issue 2
    • DOI: 10.3390/en14020283
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      Figures / Tables found in this record:

      Table 1 (p. 3)table
      Table 2 (p. 3)table
      Figure 1 (p. 4)figure
      Figure 2 (p. 6)figure
      Figure 3 (p. 7)figure
      Table 3 (p. 9)table
      Figure 4 (p. 10)figure
      Figure 5 (p. 11)figure
      Figure 6 (p. 12)figure
      Figure 7 (p. 12)figure
      Figure 8 (p. 13)figure
      Figure 9 (p. 14)figure
      Figure 10 (p. 15)figure
      Figure 11 (p. 16)figure
      Figure 12 (p. 18)figure
      Figure 13 (p. 19)figure
      Table 4 (p. 20)table
      Figure 14 (p. 22)figure
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