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The purpose of this paper is to report on the developments in manufacturing soft magnetic materials using laser powder bed fusion (L-PBF).

Ternary soft magnetic Fe-49Co-2V powder was produced by gas atomization and used in an L-PBF machine to produce samples for material characterization. The L-PBF process parameters were optimized for the material, using a design of experiments approach. The printed samples were exposed to different heat treatment cycles to improve the magnetic properties. The magnetic properties were measured with quasi-static direct current and alternating current measurements at different frequencies and magnetic flux densities. The mechanical properties were characterized with tensile tests. Electrical resistivity of the material was measured.

The optimized L-PBF process parameters resulted in very low porosity. The magnetic properties improved greatly after the heat treatments because of changes in microstructure. Based on the quasi-static DC measurement results, one of the heat treatment cycles led to magnetic saturation, permeability and coercivity values comparable to a commercial Fe-Co-V alloy. The other heat treatments resulted in abnormal grain growth and poor magnetic performance. The AC measurement results showed that the magnetic losses were relatively high in the samples owing to formation of eddy currents.

The influence of L-PBF process parameters on the microstructure was not investigated; hence, understanding the relationship between process parameters, heat treatments and magnetic properties would require more research.

The relationship between microstructure, chemical composition, heat treatments, resistivity and magnetic/mechanical properties of L-PBF processed Fe-Co-V alloy has not been reported previously.

This paper presents a comparative study of different stator-segmentation topologies of a permanent magnet synchronous machine (PMSM) used in traction drives and their effect on iron losses. Using stator segmentation allows one to achieve more significant copper fill factors, resulting in increased power densities and efficiencies. The segmentation of the stators creates additional air gaps and changes the soft magnetic material’s material properties due to the cut edge effect. The aim of this paper is to present an in-depth analysis of the influence of stator segmentation on iron losses. The main goal was to compare various segmentation methods under equal excitation conditions in terms of their influence on iron loss.

A transient finite element method analysis combined with an extended iron-loss model was used to evaluate discussed effects on the stator’s iron losses. The workflow to obtain a homogenized airgap length accounting for cut edge effects was established.

The paper concludes that the segmentation in most cases slightly decreases the iron losses in the stator because of the overall reduced magnetic flux density B due to the additional air gaps in the magnetic circuit. An increase of the individual components, as well as total power loss, was observed in the Pole Chain segmentation design. In general, segmentation did not change the total iron losses significantly. However, different segmentation methods resulted in the different distortion of the magnetic field and, consequently, in different iron loss compositions. The analysed segmentation methods exhibited different iron loss behaviour with respect to the operation points of the machine. The final finding is that analysed stator segmentations had a negligible influence on the total iron loss. Therefore, applying segmentation is an adequate measure to improve PMSMs as it enables, e.g. increase of the winding fill factor or simplifying the assembly processes, etc.

The influence of stator segmentation on iron losses was analysed. An in-depth evaluation was performed to determine how the discussed changes influence the individual iron loss components. A workflow was developed to achieve a computationally cheap homogenized model.

The purpose of this paper is to investigate an alternative to established hysteresis models.

Different mathematical representations of the magnetic hysteresis are compared and some differences are briefly discussed. After this, the application of the T(x) function is presented and an inductor model is developed. Implementation details of the used transient circuit simulator code are further discussed. From real measurement results, parameters for the model are extracted. The results of the final simulation are finally discussed and compared to measurements.

The T(x) function possesses a fast mathematical formulation with very good accuracy. It is shown that this formulation is very well suited for an implementation in transient circuit simulator codes. Simulation results using the developed model are in very good agreement with measurements.

For the purpose of this paper, only soft magnetic materials were considered. However, literature suggests, that the T(x) function can be extended to hard magnetic materials. Investigations on this topic are considered as future work.

While the mathematical background of the T(x) function is very well presented in the referenced papers, the application in a model of a real device is not very well discussed yet. The presented paper is directly applicable to typical problems in the field of power electronics.

Small highly saturated interior permanent magnet- synchronous machines (IPMSMs) show a very nonlinear behaviour. Such machines are mostly controlled with a closed-loop cascade control, which is based on a d-q two-axis dynamic model with constant concentrated parameters to calculate the control parameters. This paper aims to present the identification of a complete current- and rotor position-dependent d-q dynamic model, which is derived by using a finite element method (FEM) simulation. The machine’s constant parameters are determined for an operation on the maximum torque per ampere (MTPA) curve. The obtained MTPA control performance was evaluated on the complete FEM-based nonlinear d-q model.

A FEM model was used to determine the nonlinear properties of the complete d-q dynamic model of the IPMSM. Furthermore, a fitting procedure based on the nonlinear MTPA curve is proposed to determine adequate constant parameters for MTPA operation of the IPMSM.

The current-dependent d-q dynamic model of the machine models the relevant dynamic behaviour of the complete current- and rotor position-dependent FEM-based d-q dynamic model. The most adequate control response was achieved while using the constant parameters fitted to the nonlinear MTPA curve by using the proposed method.

The effect on the motor’s steady-state and dynamic behaviour of differently complex d-q dynamic models was evaluated. A workflow to obtain constant set of parameters for the decoupled operation in the MTPA region was developed and their effect on the control response was analysed.

In this study, AlCoCrFeNi–Cu (Cu-based) and AlCoCrFeNi–Ti (Ti-based) high entropy alloys (HEAs) were fabricated using a direct blown powder technique via laser additive manufacturing on an A301 steel baseplate for aerospace applications. The purpose of this research is to investigate the electrical resistivity and oxidation behavior of the as-built copper (Cu)- and titanium (Ti)-based alloys and to understand the alloying effect, the HEAs core effects and the influence of laser parameters on the physical properties of the alloys.

The as-received AlCoCrFeNiCu and AlCoCrFeNiTi powders were used to fabricate HEA clads on an A301 steel baseplate preheated at 400°C using a 3 kW Rofin Sinar dY044 continuous-wave laser-deposition system fitted with a KUKA robotic arm. The deposits were sectioned using an electric cutting machine and prepared by standard metallographic methods to investigate the electrical and oxidation properties of the alloys.

The results showed that the laser power had the most influence on the physical properties of the alloys. The Ti-based alloy had better resistivity than the Cu-based alloy, whereas the Cu-based alloy had better oxidation residence than the Ti-based alloy which attributed to the compositional alloying effect (Cu, aluminum and nickel) and the orderliness of the lattice, which is significantly associated with the electron transportation; consequently, the more distorted the lattice, the easier the transportation of electrons and the better the properties of the HEAs.

It is evident from the studies that the composition of HEAs and the laser processing parameters are two significant factors that influence the physical properties of laser deposited HEAs for aerospace applications.

Molecular dynamics is an emerging simulation technique in the field of machining in recent years. Many researchers have tried to simulate different processing methods of various materials with the theory of molecular dynamics (MD), and some preliminary conclusions have been obtained. However, the application of MD simulation is more limited compared with traditional finite element model (FEM) simulation technique due to the complex modeling approach and long computation time. Therefore, more studies on the MD simulations are required to provide a reliable theoretical basis for the nanoscale interpretation of grinding process. This study investigates the crystal structures, dislocations, force, temperature and subsurface damage (SSD) in the grinding of iron-nickel alloy using MD analysis.

In this study the simulation model is established on the basis of the workpiece and single cubic boron nitride (CBN) grit with embedded atom method and Morse potentials describing the forces and energies between different atoms. The effects of grinding parameters on the material microstructure are studied based on the simulation results.

When CBN grit goes through one of the grains, the arrangement of atoms within the grain will be disordered, but other grains will not be easily deformed due to the protection of the grain boundaries. Higher grinding speed and larger cutting depth can cause greater impact of grit on the atoms, and more body-centered cubic (BCC) structures will be destroyed. The dislocations will appear in grain boundaries due to the rearrangement of atoms in grinding. The increase of grinding speed results in the more transformation from BCC to amorphous structures.

This study is aimed to study the grinding of Fe-Ni alloy (maraging steel) with single grit through MD simulation method, and to reveal the microstructure evolution within the affected range of SSD layer in the workpiece. The simulation model of polycrystalline structure of Fe-Ni maraging steel and grinding process of single CBN grit is constructed based on the Voronoi algorithm. The atomic accumulation, transformation of crystal structures, evolution of dislocations as well as the generation of SSD are discussed according to the simulation results.

The purpose of this paper is to develop an algorithm and software for determining the size of a line-start permanent magnet synchronous motor (LSPMSMs) based on its optimization.

The software consists of an optimization procedure that cooperates with a FEM model to provide the desired behavior of the motor under consideration. The proposed improved version of the genetic algorithm has modifications enabling efficient optimization of LSPMSMs. The objective function consists of three important functional parameters describing the designed machine. The 2-D field-circuit mathematical model of the dynamics operation of the LSPMSMs consists of transient electromagnetic field equations, equations describing electric windings and mechanical motion equations. The model has been developed in the ANSYS Maxwell environment.

In this proposed approach, the set of design variables contains the variables describing the stator and rotor structure. The improved procedure of the optimization algorithm makes it possible to find an optimal motor structure with correct synchronization properties. The proposed modifications make the optimization procedure faster and more

This proposed approach can be successfully applied to solve the design problems of LSPMSMs.

Confronting the unveiled sophisticated structural and physical characteristics of permanent magnets, notably the samarium–cobalt (Sm-Co) alloy, This work aims to introduce a simulation scheme that can link physics-based micromagnetics on the nanostructures and magnetostatic homogenization on the mesoscale polycrystalline structures.

The simulation scheme is arranged in a multiscale fashion. The magnetization behaviors on the nanostructures examined with various orientations are surrogated as the micromagnetic-informed hysterons. The hysteresis behavior of the mesoscale polycrystalline structures with micromagnetic-informed hysterons is then evaluated by computational magnetostatic homogenization.

The micromagnetic-informed hysterons can emulate the magnetization reversal of the parameterized Sm-Co nanostructures as the local hysteresis behavior on the mesostructures. The simulation results of the mesoscale polycrystal demonstrate that the demagnetization process starts from the grain with the largest orientation angle (a) and then propagates to the surrounding grains.

The presented scheme depicts the demand for integrating data-driven methods, as the parameters of the surrogate hysteron intrinsically depend on the nanostructure and its orientation. Further hysteron parameters that help the surrogate hysteron emulate the micromagnetic-simulated magnetization reversal should be examined.

This work provides a novel multiscale scheme for simulating the polycrystalline permanent magnets’ hysteresis while recapitulating the nanoscale mechanisms, such as the nucleation of domains, and domain wall migration and pinning. This scheme can be further extended to simulate the part-level hysteresis considering the mesoscale features.

This paper aims to elaborate the method and algorithm for the analysis of the influence of temperature on back electromotive force (BEMF) waveforms in a line start permanent magnet synchronous motor (LSPMSM).

The paper presents a finite element analysis of temperature influence on BEMF and back electromotive coefficient in a LSPMSM. In this paper, a two-dimensional field model of coupled electromagnetic and thermal phenomena in the LSPMSM was presented. The influence of temperature on magnetic properties of the permanent magnets as well as on electric and thermal properties of the materials has been taken into account. Simulation results have been compared to measurements. The selected results have been presented and discussed.

The simulations results are compared with measurements to confirm the adequacy of this approach to the analysis of coupled electromagnetic-thermal problems.

The paper offers appropriate author’s software for the transient and steady-state analysis of coupled electromagnetic and thermal problems in LSPMS motor.

There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses.

Customization, comfort and functionality are the most important metrics reported by prosthetists and patients. The work of this paper presents the design and manufacturing of a custom made, cost-effective and functional three-dimensional (3D) printed transtibial prosthesis monocoque design. The design of the prosthesis integrates 3D imaging, modelling and optimization techniques coupled with additive manufacturing.

The successful fabrication of a functional monocoque prosthesis through 3D printing indicates the workflow may be a solution to the worldwide accessibility crisis. The digital workflow developed in this work offers great potential for providing prosthetic devices to rural communities, which lack access to skilled prosthetic physicians. The authors found that using the workflow together with 3D printing, this study can create custom monocoque prostheses (Figure 16). These prostheses are comfortable, functional and properly aligned. In comparison with traditional prosthetic devices, the authors slowered the average cost, weight and time of production by 95%, 55% and 95%, respectively.

This novel digital design and manufacturing workflow has the potential to democratize and globally proliferate access to prosthetic devices, which restore the patient’s mobility, quality of life and health. LIMBER’s toolbox can reach places where proper prosthetic and orthotic care is not available. The digital workflow reduces the cost of making custom devices by an order of magnitude, enabling broader reach, faster access and improved comfort. This is particularly important for children who grow quickly and need new devices every few months or years, timely access is both physically and psychologically important.

In this manuscript, the authors show the application of digital design techniques for fabricating prosthetic devices. The proposed workflow implements several advantageous changes and, most importantly, digitally blends the three components of a transtibial prosthesis into a single, 3D printable monocoque device. The development of a novel unibody transtibial device that is properly aligned and adjusted digitally, greatly reduces the number of visits an amputee must make to a clinic to have a certified prosthetist adjust and modify their prosthesis. The authors believe this novel workflow has the potential to ease the worldwide accessibility crisis for prostheses.