Review of additive manufacturing of permanent magnets for electrical machines: A prospective on wind turbine

H. Wang; T. N. Lamichhane; M. P. Paranthaman

doi:10.1016/j.mtphys.2022.100675

Review of additive manufacturing of permanent magnets for electrical machines: A prospective on wind turbine

H. Wang, T. N. Lamichhane, M. P. Paranthaman

Nanomaterials Chemistry Group

Research output: Contribution to journal › Review article › peer-review

63 Scopus citations

Abstract

Permanent magnets (PMs) power several industrial technologies that enable our modern society and high standards of living. As such technology becomes more advanced and widespread, the demand for PM-based motors and generator increases, and thus the demand for PMs themselves increases. Additive manufacturing (AM) could be an attractive method for manufacturing PMs, as it minimizes the use and waste of critical, supply-limited rare earth materials and enables near-net-shape printing of complex geometries. In this work, the critical roles that PMs play, as well as the challenges and difficulties in utilizing them, are discussed. The conventional manufacturing processes for PMs are explored, and their advantages and disadvantages are highlighted. The advantages of AM are briefly introduced. Then, a survey of the major PM materials is provided, which introduces the major magnet families and summarizes their material properties. The benefits and advantages of AM over conventional methods in creating PMs are explored in detail. After that, the AM processes that have been used to manufacture PMs are reviewed, and the AM research efforts relating to each type of these PMs are explored. The magnetic and thermal properties of AM of PMs are reported in detail. For example, printed Nd₂Fe₁₄B magnets with suitable polymers can be operated at as high as 175 °C with improved corrosion resistance. There is a focus in this paper on the use of AM PMs on wind turbine generators and large electrical machines across all sections. The future outlook of the use of AM processes for PM manufacturing is also provided.

Original language	English
Article number	100675
Journal	Materials Today Physics
Volume	24
DOIs	https://doi.org/10.1016/j.mtphys.2022.100675
State	Published - May 2022

Funding

The research was supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Wind Energy Technologies Office Program. Part of this research (MPP) was supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office. We would like to thank Latha Sethuraman and Jonathon Keller at National Renewable Energy Laboratory for providing valuable comments. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will pro-vide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The research was supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Wind Energy Technologies Office Program . Part of this research (MPP) was supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office . We would like to thank Latha Sethuraman and Jonathon Keller at National Renewable Energy Laboratory for providing valuable comments. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE) . The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will pro-vide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ).

Funders	Funder number
Critical Materials Institute
DOE Public Access Plan
Wind Energy Technologies
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Energy Efficiency and Renewable Energy

Keywords

3D printing
Additive manufacturing methods
Electrical motors
Hard magnetic materials
Magnetic properties
Multimaterials

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.mtphys.2022.100675

Cite this

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title = "Review of additive manufacturing of permanent magnets for electrical machines: A prospective on wind turbine",

abstract = "Permanent magnets (PMs) power several industrial technologies that enable our modern society and high standards of living. As such technology becomes more advanced and widespread, the demand for PM-based motors and generator increases, and thus the demand for PMs themselves increases. Additive manufacturing (AM) could be an attractive method for manufacturing PMs, as it minimizes the use and waste of critical, supply-limited rare earth materials and enables near-net-shape printing of complex geometries. In this work, the critical roles that PMs play, as well as the challenges and difficulties in utilizing them, are discussed. The conventional manufacturing processes for PMs are explored, and their advantages and disadvantages are highlighted. The advantages of AM are briefly introduced. Then, a survey of the major PM materials is provided, which introduces the major magnet families and summarizes their material properties. The benefits and advantages of AM over conventional methods in creating PMs are explored in detail. After that, the AM processes that have been used to manufacture PMs are reviewed, and the AM research efforts relating to each type of these PMs are explored. The magnetic and thermal properties of AM of PMs are reported in detail. For example, printed Nd2Fe14B magnets with suitable polymers can be operated at as high as 175 °C with improved corrosion resistance. There is a focus in this paper on the use of AM PMs on wind turbine generators and large electrical machines across all sections. The future outlook of the use of AM processes for PM manufacturing is also provided.",

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AB - Permanent magnets (PMs) power several industrial technologies that enable our modern society and high standards of living. As such technology becomes more advanced and widespread, the demand for PM-based motors and generator increases, and thus the demand for PMs themselves increases. Additive manufacturing (AM) could be an attractive method for manufacturing PMs, as it minimizes the use and waste of critical, supply-limited rare earth materials and enables near-net-shape printing of complex geometries. In this work, the critical roles that PMs play, as well as the challenges and difficulties in utilizing them, are discussed. The conventional manufacturing processes for PMs are explored, and their advantages and disadvantages are highlighted. The advantages of AM are briefly introduced. Then, a survey of the major PM materials is provided, which introduces the major magnet families and summarizes their material properties. The benefits and advantages of AM over conventional methods in creating PMs are explored in detail. After that, the AM processes that have been used to manufacture PMs are reviewed, and the AM research efforts relating to each type of these PMs are explored. The magnetic and thermal properties of AM of PMs are reported in detail. For example, printed Nd2Fe14B magnets with suitable polymers can be operated at as high as 175 °C with improved corrosion resistance. There is a focus in this paper on the use of AM PMs on wind turbine generators and large electrical machines across all sections. The future outlook of the use of AM processes for PM manufacturing is also provided.

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Review of additive manufacturing of permanent magnets for electrical machines: A prospective on wind turbine

Abstract

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Keywords

UN SDGs

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