Electromagnetic Field-Assisted Processing for Enhanced Soft Magnetic Alloys

University of Pittsburgh researchers have developed a novel method for processing bulk crystalline soft magnetic alloys using spatially selective electromagnetic fields. This innovative approach can impact the processing of these alloys in several ways, including internal heat generation, microstructure engineering, and the potential for precise engineering of magnetic structures. This technology could promote the manufacturing of high-performance motors in electric vehicles and other applications.

Description

The technology involves the application of radio frequency, microwave, and/or optical frequency electromagnetic radiation during the processing of bulk crystalline soft magnetic alloys. This results in unique physical phenomena within the material due to the detailed mechanism of electromagnetic energy absorption and much more rapid heating rates than traditional processing methods. The technology also offers new concepts and design methods for advanced motor/power components by spatially selective annealing the parts for the rotor and stator of an electrical machine.

Applications

- Advanced manufacturing
- Motor and power component design
- Electric vehicle technology

Advantages

The technology provides a viable path to exploit unprecedented properties arising from direct internal heating through induced eddy currents and other sources of dissipative losses during electromagnetic field excitation. This can enable localized and well-controlled thermal profiles for tailoring the tradeoff between mechanical and magnetic properties spatially throughout a given fabricated component. Furthermore, extremely high heating and cooling rates attainable through electromagnetic fields processing and advanced manufacturing techniques can offer unique microstructures developed under accelerated kinetics that are not otherwise achievable by traditional annealing methods.

Invention Readiness

The concept is currently at the development stage. The team has demonstrated the potential to improve the performance of large-scale inductors through “permeability engineering”. The current proposed effort seeks to extend this concept for electric motor applications by utilizing a new concept in selective heating referred to as electromagnetic field assisted thermal processing. The potential benefits of the proposed approach will be quantified through simulation.

IP Status

https://patents.google.com/patent/US20240271236A1