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Energies
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Advanced Manufacturing and Materials for Next Generation Electrical Machines
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Advanced Manufacturing and Materials for Next Generation Electrical Machines

A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "F: Electrical Engineering".

Deadline for manuscript submissions: closed (15 April 2023) | Viewed by 17940

Special Issue Editors

Dr. Silvio Vaschetto

E-Mail Website
Guest Editor
Dipartimento Energia, Politecnico di Torino, Torino, Italy
Interests: electric machines; induction machines; synchronous machines; high efficiency; advanced materials; thermal analysis
Special Issues, Collections and Topics in MDPI journals
Dr. João Filipe Pereira Fernandes

E-Mail Website
Guest Editor
Instituto de Engenharia Mecânica (IDMEC), Instituto Superior Técnico (IST), Universidade Lisboa (UL), Lisbon, Portugal
Interests: electrical machines design and optimization; core and coreless superconducting machines; alternative for rare-earth electrical machines; special materials to reduce saturation in the magnetic circuit core; electrical machines for aircraft and automotive applications
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With the continuous electrification of the industry and transportation systems, higher specifications are demanded for electrical machines. In particular, to make urgent action on climate change, several countries are focusing their efforts on the electrification of both private and public transports, including aeronautical and naval transportations. Such a paradigm shift imposes the need to extend the current limits of the electrical machines at torque and power density values that conventional machines still do not achieve. To achieve these targets, the application of new materials, advanced additive manufacturing technologies and 3D printing solutions, innovative cooling techniques and new electrical machine designs present, today, an opportunity to overcome these challenges.

Recent developments in additive manufacturing promote more efficient manufacturing, with low material waste, high-flexibility, and new non-conventional machine geometries. To achieve the correct implementation of these techniques, all aspects of the machine must be integrated at all stages of the manufacturing process, including all active parts in the process, and consider their mechanical, electromagnetic, and thermal performance and mutual influences. The metrics for evaluating the inclusion of advanced electromagnetic materials and the use of advanced manufacturing techniques must be used. To complement the conventional metrics, such as specific power, efficiency, and cost, the lifecycle assessment of each active part and of the whole machine can be used to provide important feedback for an estimation of the machine lifetime.

Advanced manufacturing and materials for next generation electrical machines are an important research topic with a direct impact on industrial and transportation applications.

This Special Issue invites original research papers to address the latest findings in advanced manufacturing and new electromagnetic materials for next generation electrical machines. Topics of interest for publication include but are not limited to:

  • Advanced electromagnetic materials;
  • Manufacturing technologies for electric machines;
  • Additive manufacturing and 3D printing;
  • Lifecycle assessment;
  • High-specific power electrical machines;
  • Cooling techniques;
  • Cryogenic electrical machines;
  • Design, modelling and optimization;
  • Novel designs and topologies of electrical machines;
  • Prototyping techniques.

Prof. Dr. Silvio Vaschetto
Prof. Dr. João Filipe Pereira Fernandes
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Energies is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • advanced electromagnetic materials
  • manufacturing technologies for electric machines
  • additive manufacturing and 3D printing
  • lifecycle assessment
  • high-specific power electrical machines
  • cooling techniques
  • cryogenic electrical machines
  • design, modelling and optimization
  • novel designs and topologies of electrical machines
  • prototyping techniques

Published Papers (4 papers)

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Research

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16 pages, 9355 KiB  
Article
Effect of Magnetic Properties of Magnetic Composite Tapes on Motor Losses
by Ryo Yoshida, Jun Kitajima, Takashi Sakae, Mitsuhide Sato, Tsutomu Mizuno, Yuki Shimoda, Akihiro Kubota, Shogo Wada, Teruo Kichiji and Hideo Kumagai
Energies 2022, 15(21), 7991; https://doi.org/10.3390/en15217991 - 27 Oct 2022
Cited by 4 | Viewed by 1765
Abstract
Alternating current (AC) copper losses in motors increase with carrier frequency of the pulse width modulation (PWM) and are further increased by leakage flux of the permanent magnet. Therefore, AC copper losses increase with motor speed. Conventional techniques for reducing AC copper losses [...] Read more.
Alternating current (AC) copper losses in motors increase with carrier frequency of the pulse width modulation (PWM) and are further increased by leakage flux of the permanent magnet. Therefore, AC copper losses increase with motor speed. Conventional techniques for reducing AC copper losses tend to increase other losses. In this paper, AC copper loss was reduced by wrapping a magnetic tape made of a magnetic composite material around the winding. This method controlled the flux path through the winding. Magnetic composite materials are mixtures of magnetic powders and liquid resins whose magnetic properties can be manipulated by changing the combination and other factors. When Fe–Si–Al magnetic tape was wrapped around the winding, the AC copper loss was reduced by 40%. The loss was further reduced by optimizing the magnetic properties of the magnetic composite material. The AC copper loss was maximally reduced when the specific permeability was 100 and the saturation flux density was 1.6. Magnetic tapes composed of magnetic composite materials with high saturation flux density and specific permeability reduce the AC copper losses without increasing other losses in the motor. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Materials for Next Generation Electrical Machines)
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26 pages, 9470 KiB  
Article
Laser Additively Manufactured Magnetic Core Design and Process for Electrical Machine Applications
by Hans Tiismus, Ants Kallaste, Toomas Vaimann, Liina Lind, Indrek Virro, Anton Rassõlkin and Tatjana Dedova
Energies 2022, 15(10), 3665; https://doi.org/10.3390/en15103665 - 17 May 2022
Cited by 13 | Viewed by 4328
Abstract
Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by [...] Read more.
Additive manufacturing (AM) is considered the enabling technology for topology optimized components, with its unparalleled, almost free-form design freedom. Over the past decade, AM of electromagnetic materials has evolved into a promising new area of research. Considerable efforts have also been invested by the electrical machine (EM) research community to develop and integrate novel additive components. Several challenges remain, however, in printing soft magnetic flux guides—most prominently, reducing the induced eddy currents to achieve competitive AM core efficiency. This paper demonstrates the workflow of laser additive manufacturing magnetic cores with superior magnetic properties to soft magnetic composites (at 50 Hz excitation): describing the workflow, parameter tuning for both printing and annealing, and shape optimization. Process optimization yielded the optimal energy density of 77 J/mm3 and annealing temperature of 1200 °C, applied to prepare the samples with the highest relative density (99.86%), lowest surface roughness Rz (0.041 mm), minimal hysteresis losses (0.8 W/kg at 1.0 T, 50 Hz), and ultimate yield strength of 420 MPa. For Eddy current suppression, the sample (5 × 5 × 60 mm toroid) with bi-directional grading reached specific core losses as low as 1.8 W/kg (W10,50). Based on the findings, the advantages and disadvantages of AM graded cores are discussed in detail. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Materials for Next Generation Electrical Machines)
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Review

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18 pages, 1597 KiB  
Review
A Review of Technology Readiness Levels for Superconducting Electric Machinery
by Bárbara Maria Oliveira Santos, Fernando Jorge Monteiro Dias, Frederic Trillaud, Guilherme Gonçalves Sotelo and Rubens de Andrade Junior
Energies 2023, 16(16), 5955; https://doi.org/10.3390/en16165955 - 12 Aug 2023
Cited by 3 | Viewed by 1461
Abstract
Superconducting electric machines (SEMs) have the potential to be commercially available in the coming years. This commercialization depends on the availability of high-temperature superconductors (HTS) produced on a large scale. HTSs have high current densities and low losses, making them the leading technology [...] Read more.
Superconducting electric machines (SEMs) have the potential to be commercially available in the coming years. This commercialization depends on the availability of high-temperature superconductors (HTS) produced on a large scale. HTSs have high current densities and low losses, making them the leading technology choice for future light and compact high-power-density superconducting rotating machines, with a particular niche for high torque at low frequency. The advantages of SEM in its fully superconducting design or hybrid configuration (conventional stator, superconducting rotor) inherit from the characteristics of the superconductor material. So, they can show greater efficiency at a higher power density and lighter frame than their conventional counterparts for an equivalent power rating. Applications like electric aircraft, naval propulsion, and wind turbines, among others, are likely to use SEMs if the rated power has to be increased beyond what is technically available with conventional technology. In this context, this paper reviews SEMs and their applications. However, it also aims to highlight the main the literature projects with a minimal Technology Readiness Level (TRL) larger than three. Due to the diversity of the superconductors’ characteristics and the variety of machines, the modes of operation of SEMs can be quite distinct from conventional machines. Taking into account such diversity, SEMs are presented and sorted out by their operational principles and the choice of superconducting material. Finally, the future perspectives of SEM are discussed. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Materials for Next Generation Electrical Machines)
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18 pages, 164436 KiB  
Review
Metal Additive Manufacturing for Electrical Machines: Technology Review and Latest Advancements
by Ahmed Selema, Mohamed N. Ibrahim and Peter Sergeant
Energies 2022, 15(3), 1076; https://doi.org/10.3390/en15031076 - 31 Jan 2022
Cited by 56 | Viewed by 9216
Abstract
Metal additive manufacturing (AM) has been growing remarkably in the past few years. Thanks to the advantages of unmatched flexibility and zero material waste, this clean technology opens the door for new design solutions with greater material efficiency, which are not possible through [...] Read more.
Metal additive manufacturing (AM) has been growing remarkably in the past few years. Thanks to the advantages of unmatched flexibility and zero material waste, this clean technology opens the door for new design solutions with greater material efficiency, which are not possible through conventional machining techniques. In this paper, we provide a technology overview of metal AM techniques that can be utilized in a wide range of applications, including constructing electrical machines. Different techniques of metal AM are discussed and compared. Additionally, the impact of the material forms (powder/wire) on printing speed and quality are studied. Based on the industrial and technical literature, this paper provides a comprehensive review of metal AM in the fabrication of electrical machines and their applications. This includes the current state of the art and associated benefits of AM in these applications. Full article
(This article belongs to the Special Issue Advanced Manufacturing and Materials for Next Generation Electrical Machines)
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