Loss Characterisation of Additively Manufactured Windings for Aerospace Propulsion Motors

Abstract

This study presents an electrical loss characterisation of laser powder bed fusion (LPBF) additively manufactured copper windings for aerospace propulsion motors (APMs). Limited manufacturing flexibility in conventional processes restricts the realisation of optimised three-dimensional conductor geometries, whereas metal additive manufacturing (AM) can relax these constraints; however, the electrical performance of AM windings must be demonstrated to be comparable to that of conventionally manufactured windings before AM-enabled benefits can be exploited. 2D finite-element analysis (FEA) is employed to evaluate the influence of temperature and current excitation on AC copper losses, while 3D FEA is used to quantify end winding impact and to decompose the dominant AC loss components. Experimental measurements on an LPBF edgewise coil mounted on a stator and benchmarked against a commercially manufactured edgewise coil validate the modelling approach and demonstrate comparable loss behaviour for the investigated geometry. The results indicate the suitability of AM for rapid prototyping and tailored winding manufacture; however, application-ready deployment still requires insulation and thermal/dielectric qualification. In the present prototype, interlayer insulation is provided using Kapton tape as a laboratory solution.