Electrical Conductivity of Additively Manufactured Copper and Silver for Electrical Winding Applications.
Electrical Conductivity of Additively Manufactured Copper and Silver for Electrical Winding Applications.
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DOI：
10.3390/ma15217563
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发表时间：
2022-10-28
期刊：
影响因子：
--
通讯作者：
Lyall I
中科院分区：
文献类型：
--
作者：
Robinson J;Munagala SP;Arjunan A;Simpson N;Jones R;Baroutaji A;Govindaraman LT;Lyall I
高效、功率密集的电机对于推动汽车、航空航天和能源等许多行业的下一代绿色能源技术至关重要。然而，实现这一目标的主要要求之一是使用优化的材料和几何形状制造紧凑的定制绕组。电机绕组依赖于高导电材料，因此，定制铜 (Cu) 和银 (Ag) 绕组的增材制造 (AM) 提供了通过优化材料、定制几何形状和拓扑以及通过集成冷却策略进行热管理来同时提高效率的机会。激光粉床熔融 (L-PBF) 是最成熟的金属增材制造技术，然而，由于能量吸收不足，激光加工铜和银等高反射性和导电性金属极具挑战性。在这方面，本研究详细介绍了高纯铜、银和铜银合金的 400 W L-PBF 处理以及由此产生的导电性能。四项比较研究对六种铜和银材料变体进行了研究，表征了材料成分、粉末重涂、激光曝光和电解抛光的影响。达到的最高密度和电导率分别为 88% 和 73% IACS。为了帮助应用电绝缘涂层，建立了电解抛光参数以改善表面粗糙度。最后，制造了概念验证电机线圈，凸显了铜和银 400 W L-PBF 加工的潜力，扩展了当前的技术水平。
Efficient and power-dense electrical machines are critical in driving the next generation of green energy technologies for many industries including automotive, aerospace and energy. However, one of the primary requirements to enable this is the fabrication of compact custom windings with optimised materials and geometries. Electrical machine windings rely on highly electrically conductive materials, and therefore, the Additive Manufacturing (AM) of custom copper (Cu) and silver (Ag) windings offers opportunities to simultaneously improve efficiency through optimised materials, custom geometries and topology and thermal management through integrated cooling strategies. Laser Powder Bed Fusion (L-PBF) is the most mature AM technology for metals, however, laser processing highly reflective and conductive metals such as Cu and Ag is highly challenging due to insufficient energy absorption. In this regard, this study details the 400 W L-PBF processing of high-purity Cu, Ag and Cu–Ag alloys and the resultant electrical conductivity performance. Six Cu and Ag material variants are investigated in four comparative studies characterising the influence of material composition, powder recoating, laser exposure and electropolishing. The highest density and electrical conductivity achieved was 88% and 73% IACS, respectively. To aid in the application of electrical insulation coatings, electropolishing parameters are established to improve surface roughness. Finally, proof-of-concept electrical machine coils are fabricated, highlighting the potential for 400 W L-PBF processing of Cu and Ag, extending the current state of the art.
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DOI：
10.1016/j.jmatprotec.2021.117130
发表时间：
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影响因子：
6.3
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