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 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 Nd2Fe14B (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.