A Low-Loss High Saturation Fe-Co Alloy for High Power Density Aircraft Electric Motors

In high-power density applications, motor iron cores usually suffer from high magnetic saturation under high frequency. In this paper, a method for manufacturing low-loss iron cores tailored for high-power-density aircraft electric motors is introduced. Laminations of Fe-Co alloy 1J22 with a thickness of 0.1 mm are selected as the research object, and two stacking processes, namely the vacuum pressure impregnating (VPI) and adhesive varnish spraying and lamination process (AVSLP), are investigated to analyze the impact of different stacking and sticking methods on the iron loss of 1J22 laminates. Experimental results demonstrate that within the lamination factor range of 0.90 to 0.96, utilizing AVSLP with X98-11 proves to be an effective approach for producing low-loss iron cores. This method achieves an iron loss of 97.79 W/kg at 2.0 T 1000 Hz and 19.08 W/kg at 1.5 T 400 Hz, which is promising in high-power density applications, especially in high-power density aircraft electric motors.