Properties of Additively Manufactured Soft and Hard Magnetic Cores for Electrical Machines: Methods and Materials − A Review

Abstract

Additive Manufacturing (AM) is an emerging topic in the field of electrical machines (EMs), offering the potential to overcome challenges imposed by conventional manufacturing methods. This paper provides an overview of various AM methods and materials used to manufacture soft and hard magnetic cores for EMs, with a particular focus on their multiphysics properties. Since each AM method involves unique processes—such as particle bonding, melting, or sintering—the resulting microstructural properties of the printed cores differ, leading to varied multi-physics characteristics that require indepth study. The paper outlines both the benefits and challenges associated with AM techniques and materials. Importantly, it explores the detailed properties of Fe-Si and Fe-Co soft magnetic cores as well as hard magnetic cores including NdFeB, ferrite, and alnico printed through different AM methods, comparing them to traditional laminations and commercial hard magnets.