Eddy Current Loss Reduction in Binder Jet Printed Iron Silicon

One of the key features of any electric machine is high efficiency, which in turn means keeping losses to a minimum. Recent advances in the field of additive manufacturing show that the addition of boron to binder jet printed iron silicon improves magnetic properties. However, there has been little success in reducing the eddy current losses at higher frequencies. In this work, the effect of boron particle size on total loss in binder jet printed iron silicon steel was evaluated. Both quasi-static and ac magnetic characterization were used to analyze the magnetic properties. Bulk resistivity is measured using four-probe method. Finally, the microstructure was analyzed using scanning electron microscopy to study the grain boundary as well as quantify the grain size and porosity.

I. Introduction

With the world focused on reduction of carbon emissions in order to impact the environment in a positive manner, electric machines are fast becoming an even more indispensable part of our lives. Additive manufacturing (3D printing) can be a valuable tool in the area of electric machine design. The most important advantage of 3D printing is its ability to produce parts with complex geometries using minimal tooling and economic means of fabrication. The flexibility enabled by 3D printing can potentially facilitate development of the next generation electrical machines.