Search

This study explores the application of AncorLam HR (Höganäs, Sweden), a soft magnetic composite material, in the stator core of an axial flux permanent magnet drive motor. Building on previous research that provided mechanical and thermal properties of the material, the focus is on analyzing how the manufacturing process affects the motor core's shape. A bulk prototype was created based on case 3, which demonstrated the least deviation in density and internal stress. The prototypes were produced under the conditions of SPM 7 and 90 °C, and a heat treatment in a nitrogen atmosphere for 1 h, resulting in an average density error of 0.54%, confirming process effectiveness. A microstructural analysis using scanning electron microscopy (SEM) on Sample 2, with the highest density, confirmed consistency between simulation and prototype trends. Electron backscatter diffraction (EBSD) and X-ray diffraction (XRD) analyses revealed that the internal phase structure remained unchanged. Energy-dispersive spectroscopy (EDS) and transmission electron microscopy (TEM) identified the elimination of phosphorus (P) during molding, affecting the insulating layer, a critical factor for SMC materials. In motor simulations and actual measurements, the average torque was recorded as 37.7 N·m and 34.7 N·m at 1500 rpm and 27.7 N·m and 25.1 N·m at 2000 rpm, respectively. The torque comparison observed in the actual measurements compared to the simulation results indicates that the output loss increases in the actual measurements due to the deterioration of the insulation performance judged based on the microstructure evaluation. This study confirms the viability of using AncorLam HR in motor cores for electric vehicles and provides key data for improving the performance. [ABSTRACT FROM AUTHOR]

The powder metallurgy process of manufacturing the motor core and inductor core using SMC greatly changes formability depending on the process variables. Therefore, this study explored the optimal process conditions of the powder metallurgy of the SMC stator core using Fe-6.5 wt.%Si by applying the Taguchi method, and selected deviations between the maximum and minimum relative densities as characteristic values; selected the formation pressure, molding temperature, and heating time as control factors; and derived the process conditions with the maximum SNR. As a result, the molding pressure was 120 MPa, the molding temperature was 500 °C, and the heating time was 120 s, and the material properties of the electrical properties' core loss, saturation flux density, and bulk conductivity were measured and analyzed. After that, a prototype was produced, the analysis was verified, the mechanical properties were verified by performing density and SEM analysis at 15, 9, and 3 mm points based on the press vertical direction, and a motor was manufactured to verify the electrical properties. [ABSTRACT FROM AUTHOR]

This study systematically investigates the impact of the material properties of soft magnetic composites (SMCs) on the powder metallurgy forming process. It proposes a suitable material selection process for various motor types and shapes and determines the optimal forming conditions for each SMC material. This study employed the Taguchi design method to identify key control factors such as powder type, forming temperature, and forming speed, and analyzed their effects on relative density. Simulation results indicated that AncorLam HR exhibited superior properties compared with AncorLam and Fe-6.5wt.%Si. The optimal conditions determined through signal-to-noise ratio (SNR) calculations were AncorLam HR at 60 °C and five cycles per minute (CPMs). Validation through simulation and SEM analysis confirmed improved density uniformity and reduced defects in products formed under optimal conditions. Final prototype testing demonstrated that the selected conditions achieved the target density with minimal variance, enhancing the mechanical properties and performance of the motors. These results suggest that the appropriate application of SMC materials can significantly enhance motor efficiency and reliability. [ABSTRACT FROM AUTHOR]