Frequency- and Temperature-Dependent Uncertainties in Hysteresis Measurements of a 3D-Printed FeSi wt6.5% Material

Additive manufacturing of soft magnetic materials is a promising technology for creating topologically optimized electrical machines. High-performance electrical machines can be made from high-silicon-content FeSi alloys. Fe-6.5wt%Si material has exceptional magnetic properties; however, manufacturing this steel with the classical cold rolling methodology is not possible due to the brittleness of this material. Laser powder bed fusion technology (L-PBF) offers a solution to this problem. Finding the optimal printing parameters is a challenging task. Nevertheless, it is crucial to resolve the brittleness of the created materials so they can be used in commercial applications. The temperature dependence of magnetic hysteresis properties of Fe-6.5wt%Si materials is presented in this paper. The magnetic hysteresis properties were examined from 20 °C to 120 °C. The hysteresis measurements were made by a precision current generator-based hysteresis measurement tool, which uses fast Fourier transformation-based filtering techniques to increase the accuracy of the measurements. The details of the applied scalar hysteresis sensor and the measurement uncertainties were discussed first in the paper; then, three characteristic points of the static hysteresis curve of the ten L-PBF-manufactured identical toroidal cores were investigated and compared at different temperatures. These measurements show that, despite the volumetric ratio of the porosities being below 0.5%, the mean crack length in the samples is not significant for the examined samples. These small defects can cause a significant 5% decrement in some characteristic values of the examined hysteresis curve.