SBIR Phase I: Spray-Formed Soft Magnetic Material for Efficient Hybrid-Field Electric Machines

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This Small Business Innovation Research (SBIR) Phase I project aims to develop a novel soft magnetic material for electric motor cores, a fabrication process to make components from the material, and an electric motor configuration leveraging the benefits of the material and fabrication process. The approach is to utilize a new single-step net-shape fabrication technique based on uniform-droplet spray deposition in a reactive atmosphere to produce an isotropic metal microstructure characterized by small domains of high permeability and low coercivity with a controlled formation of insulation boundaries that limit electrical conductivity between neighboring domains. This design is expected to provide a superior magnetic path while minimizing losses due to eddy currents, and eliminating design constraints associated with anisotropic laminated cores of conventional motors.The broader/commercial impact of this project will be the potential to provide spray-formed winding cores for hybrid-field motors to increase output, improve efficiency and reduce material scrap during fabrication, thus lowering the cost of electric motors. Considering the extensive use of electric motors in numerous applications, including industrial machinery and automation, robotics, heating, ventilation and air conditioning systems, appliances, power tools, medical devices, automotive applications, electric vehicles, military equipment etc., there is an increasing need for electric motors with improved performance, higher efficiency, and lower cost. This project is expected to have a significant commercial and environmental impact by providing low-cost and high-efficiency electric motor cores.