Additive manufacturing of low loss magnetic alloys by 3D lamination – FALSTAFF

FALSTAFF aims to provide technological bricks leading to a limitation of eddy current losses in magnetic components and to a general optimization of magnetic performance in the high frequency field, leading to a major breakthrough in the design of electrical machines, high performance alternating current. To do this, FALSTAFF will explore new, innovative ways of producing ferromagnetic alloys in the form of 3D laminated components, combining magnetic and insulating structures. Two methods, based on the LBM or DED process, will be proposed, by the porous route or by combining two materials. To this end, the project covers, in a balanced partnership, all of the design stages. Metal powders of two compositions, Fe-6.5 wt.% Si and Fe-Co-V, will be produced by atomization (WP 1). Laminated test pieces will be manufactured, exploring different construction parameters and strategies, and integrating heat treatments (WP 2 and 5). In-depth characterization will be developed on the components, making it possible to analyse the link between process parameters and microstructural, chemical and mechanical properties, as well as defects occurrence (WP 3). In parallel, a thermomechanical modelling of the process, coupled with a CAFE approach, will be developed, at meso- and macro- scales, allowing the study of the development of grain structures under construction, and the resulting textures (WP 4). Thermodynamic couplings will lead to the investigation of composition effects. A fine magnetic characterization of the parts will be developed (WP 5) and compared to experimental observations and model outputs. The specific properties of the alloys and the proposed construction strategies will thus be determined. Development conditions maximizing the properties of laminated structures will be defined.