AUTOMOTIVE
A Case Study in the Automotive Industry
Title:
Superior Magnetic Properties in Structurally-Tailored 3D-Printed Electric Motor Cores
Project Scope:
The project focuses on optimizing the 3D printing process for FeSi alloys with high silicon content (up to 20%) used in electric motor (EM) cores. The goal is to enhance magnetic properties while minimizing defects like cracks and reducing the need for costly post-processing.
Challenge:
FeSi alloys, particularly those with high silicon content, are highly desirable in the automotive industry for their superior magnetic properties. However, these alloys are prone to cracking during 3D printing due to the formation of unwanted intermetallic phases and residual stresses. Traditional manufacturing methods struggle with processing these alloys, leading to high power losses at higher switching frequencies and the need for extensive post-processing to improve magnetic performance.
Solution:
OptiFab’s novel approach integrates advanced microstructure engineering with AI-driven control to optimize the 3D printing process. This involves managing thermal distribution during printing to prevent cracks, controlling the material microstructure to enhance magnetic performance, and minimizing residual stress and orientation sensitivity. The solution allows for the production of high-quality, “as-printed” FeSi alloy components with superior magnetic properties and mechanical performance.
Expected Outcome:
1) Crack-Free Components: Manufacturing components that are free of cracks, with a density exceeding 99.99%, resulting in superior mechanical performance.
2) Reduced Power Loss: Achieving a 50% reduction in power loss at both low and high frequencies in the “as-printed” condition, enhancing the efficiency of electric motor cores.
3) Enhanced Magnetic Properties: Increasing saturation magnetization and permeability by 50% in the “as-printed” condition, leading to improved magnetic performance in electric motors.
4) Cost Reduction: Eliminating the need for costly post-processing, such as heat treatment, due to the minimized residual stress and other non-uniformities in the “as-printed” condition.
Key Benefits of OptiFab’s Solution:
1) Thermal Management: Effective management of thermal distribution during 3D printing, resulting in crack-free components with minimal distortion, enhancing part quality and efficiency.
2) Microstructure Control: Precise control over material microstructure and performance at any given location, ensuring consistency and reliability throughout the part.
3) Cost Efficiency: Reduction of production costs by minimizing orientation sensitivity, residual stress, and the need for post-processing.
KPIs (Key Performance Indicators):
1) Crack-Free Density: Target of achieving >99.99% density in 3D-printed FeSi components.
2) Power Loss Reduction: 50% reduction in power loss at low and high frequencies.
3) Magnetic Property Improvement: 50% increase in saturation magnetization and permeability in “as-printed” FeSi components.
4) Cost Savings: Complete elimination of post-processing costs, such as heat treatment, by minimizing residual stress and other non-uniformities.
Additional Information:
This project highlights the potential of OptiFab’s solution to revolutionize the production of electric motor cores in the automotive industry, making it possible to achieve superior magnetic properties and mechanical performance without the drawbacks of traditional manufacturing methods. The integration of AI-driven control and microstructure engineering ensures that the components are optimized for both performance and cost-efficiency, positioning OptiFab as a key enabler of advanced automotive manufacturing.
Note:
This case study is based on ongoing commercial discussions.
