Structurally-layered soft magnetic Fe-Si components with surface insulation prepared by shell-shaping selective laser melting
Structurally-layered soft magnetic Fe-Si components with surface insulation prepared by shell-shaping selective laser melting
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壳形选区激光熔化制备表面绝缘层状软磁铁硅元件
DOI：
10.1016/j.apsusc.2021.149510
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发表时间：
2021
影响因子：
6.7
通讯作者：
J. Jeong
中科院分区：
文献类型：
--
作者：
Bonuk Koo;Min;Y. Nam;Sangsun Yang;Jihun Yu;Y. Park;J. Jeong
近年来，软磁元件（SMCs）的选择性激光熔化（SLM）由于其在难以成形的高性能合金（例如Fe-6.5 wt%Si）的三维成形方面的高精度而引起了人们的极大兴趣，这些合金正在被高度追求以实现小而轻的下一代电动机。然而，由于没有合适的绝缘材料来承受极高温激光加工，具有内部绝缘的SLMed SMCs从未被成功证明。在这里，我们介绍了一种新的壳体成形选择性激光熔化（SS-SLM）工艺，并展示了高密度（相对密度> 98%）具有表面绝缘的结构层状Fe-6.5 wt% SMCs。特别是，高温热处理诱导晶粒生长，显著增强磁性能，矫顽力为34.6 A/m，磁导率为7393，饱和磁化强度为1.68 t。此外，溶胶-凝胶基工艺在壳体表面形成均匀致密的sio2绝缘层，有效地限制了壳体内的涡流。值得注意的是，在可定义的最小薄片厚度为0.2 mm的情况下，芯损耗为52.5 W/kg（在1 kHz， Bm= 1 T时）。最后，我们展示了具有表面绝缘的结构层状SMCs（新型轴向磁通电机的定子），最终可用于实现三维优化磁路，并以高效率大幅提高功率密度。
Recently, selective laser melting (SLM) of soft magnetic components (SMCs) has attracted great interest due to its high accuracy in three-dimensional shaping of hard-to-form high performance alloys (e.g. Fe-6.5 wt%Si), which are being highly pursued for the realization of small and lightweight next-generation electric motors. However, SLMed SMCs with internal insulation have never been successfully demonstrated because there are no suitable insulation materials to withstand extremely-high-temperature laser processing. Here we introduce a novel shell-shaping selective laser melting (SS-SLM) process and demonstrate highly-dense (relative density > 98%) structurally-layered Fe-6.5 wt% SMCs with surface insulation. In particular, high-temperature heat treatment induced grain growth and dramatically enhanced magnetic properties, including coercivity of 34.6 A/m, permeability of 7393, and saturation magnetization of 1.68 T. Furthermore, a sol-gel-based process yielded a uniform and dense SiO2insulation layer on the shell surface, which effectively confines eddy current only in the shell. Remarkably, core loss of 52.5 W/kg (at 1 kHz, Bm= 1 T) was observed with definable minimum sheet thickness of 0.2 mm. Finally, we demonstrate structurally-layered SMCs (stators for novel axial-flux motors) with surface insulation, which eventually can be used to realize a three-dimensionally optimized magnetic path and considerably increased power density with high efficiency.