Abstract Additive manufacturing (AM) of functional alloys has become a promising area of research for the development of novel devices with complex geometric features that cannot be manufactured using conventional methods. In this work, we investigate the additive manufacturing of Fe 3Si and Fe 6Si benchtop scale transformer cores. A novel design inspired by a Hilbert curve was developed to exploit the geometric complexity of AM, and cores of each alloy were successfully printed, heat treated, machined, pickled, and assembled. The microstructure and magnetic performance of the cores were characterized and compared to additively manufactured components with simpler square cross-sections as well as to conventionally laminated non-oriented electrical steel sheet. The AM cores showed performance roughly comparable or better than the conventional non-oriented sheet, but higher power losses than Goss oriented steel. The increased Si content of the Fe 6Si alloy resulted in a significant reduction in core losses. The transformer cores had higher losses than the similarly manufactured simple cross-sections, which was attributed to defects in fabrication and assembly that resulted in air gaps between the transformer legs. The performance was also rationalized relative to nanoscale carbide and oxide inclusions.

中文翻译：

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增材制造的高硅变压器磁芯的设计与性能

摘要 功能合金的增材制造 (AM) 已成为开发具有复杂几何特征的新型器件的有前途的研究领域，这些器件无法使用传统方法制造。在这项工作中，我们研究了 Fe 3Si 和 Fe 6Si 台式变压器铁芯的增材制造。一种受希尔伯特曲线启发的新颖设计被开发出来，以利用 AM 的几何复杂性，每种合金的核心都成功地打印、热处理、加工、酸洗和组装。对磁芯的微观结构和磁性能进行表征，并将其与具有更简单方形横截面的增材制造部件以及常规层压无取向电工钢板进行比较。AM 磁芯的性能与传统的无取向板大致相当或更好，但功率损耗高于 Goss 取向钢。Fe 6Si 合金中增加的硅含量导致磁芯损耗的显着降低。变压器铁芯的损耗高于类似制造的简单横截面，这是由于制造和组装中的缺陷导致变压器支腿之间存在气隙。相对于纳米级碳化物和氧化物夹杂物，性能也得到了合理化。这是由于制造和组装中的缺陷导致变压器腿之间存在气隙。相对于纳米级碳化物和氧化物夹杂物，性能也得到了合理化。这是由于制造和组装中的缺陷导致变压器腿之间存在气隙。相对于纳米级碳化物和氧化物夹杂物，性能也得到了合理化。