Additive manufacturing of Fe-6.5 wt.%Si transformer steel toroidal cores: Process optimization, design aspects, and performance

Ali Zayaan Macknojia; John V. Tran; Michael P. McKinstry; Juan Galindo; Yuqi Jin; Shelden Dowden; Shreyash M. Patil; Mangesh V. Pantawane; K.V. Mani Krishna; Rajarshi Banerjee; Sameehan S. Joshi; Narendra B. Dahotre

Materials & Design (May 2024)

Additive manufacturing of Fe-6.5 wt.%Si transformer steel toroidal cores: Process optimization, design aspects, and performance

Ali Zayaan Macknojia,
John V. Tran,
Michael P. McKinstry,
Juan Galindo,
Yuqi Jin,
Shelden Dowden,
Shreyash M. Patil,
Mangesh V. Pantawane,
K.V. Mani Krishna,
Rajarshi Banerjee,
Sameehan S. Joshi,
Narendra B. Dahotre

Affiliations

Ali Zayaan Macknojia: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
John V. Tran: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Michael P. McKinstry: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Department of Physics, University of North Texas, 210 Ave A, Denton, TX 76201, USA
Juan Galindo: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Yuqi Jin: Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Shelden Dowden: Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Shreyash M. Patil: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Mangesh V. Pantawane: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Currently at The Timken Company, Canton, OH, USA
K.V. Mani Krishna: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Rajarshi Banerjee: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Sameehan S. Joshi: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA
Narendra B. Dahotre: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Center for Agile and Adaptive Additive Manufacturing, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA; Corresponding author at: Department of Materials Science and Engineering, University of North Texas, 3940 N Elm St, Denton, TX 76207, USA.

Journal volume & issue: Vol. 241
p. 112883

Abstract

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Fe-Si electrical steels are conventionally popular materials for transformer application. Although higher Si (4wt.%<) content is favorable for increasing the resistivity and improving the soft magnetic properties, fabrication of transformer core with higher Si containing electrical steels is difficult by conventional wrought processes due to an increase in its brittleness. Additive manufacturing provides a novel alternative plausible way to fabricate transformer cores with higher Si content and unique design features. The current work focused on process optimization and design aspects of laser powder bed fusion additive manufacturing of Fe-6.5wt.% electrical steel. Additively manufactured components with 99.5% relative density were produced. The optimally fabricated component contained columnar grains of α-FeSi phase morphologically oriented in the build direction. The optimally fabricated Fe-6.5wt.% component was also subjected to annealing treatment at 1150∘C for 1 h in Ar resulting in multi-fold grain growth and improved soft magnetic response. Based on optimal laser processing parameters, 3 different designs for toroidal cores with slit patterns for varying degree of cross-sectional areas were additively fabricated. The toroidal cores were subjected to same annealing treatment as that of the additively fabricated component. Core with least cross-sectional area exhibited improved magnetic performance compared to the other designs.

Published in Materials & Design

ISSN: 0264-1275 (Print); 1873-4197 (Online)
Publisher: Elsevier
Country of publisher: United Kingdom
LCC subjects: Technology: Electrical engineering. Electronics. Nuclear engineering: Materials of engineering and construction. Mechanics of materials
Website: https://www.journals.elsevier.com/materials-and-design

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