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- Maschinenbau und Werkstofftechnik (81) (remove)
In elektrischen Maschinen werden zur Führung des magnetischen Flusses Eisenkerne aus voneinander isolierten, dünnen Elektroblechlamellen verwendet. Die weichmagnetischen Eigenschaften und der im Vergleich zu reinem Eisen erhöhte elektrische Widerstand dieses Werkstoffs sind essentiell für die Leistung und den Wirkungsgrad der Maschine. Bis zum fertigen Eisenkern beziehungsweise bis zum fertigen Antrieb durchläuft das Elektroband mehrere Fertigungsschritte. Durch das formgebende Schneiden werden die magnetischen Eigenschaften im Schnittkantenbereich beeinflusst, wodurch die Eisenverluste erhöht werden und die Polarisierbarkeit gesenkt wird. Darüber hinaus werden bei der Montage der Eisenkerne zusätzlich mechanische Spannungen in das Material eingebracht, was sich ebenfalls negativ auf die Performance der elektrischen Maschine auswirkt. Gegenstand dieser Arbeit ist die experimentelle Untersuchung der genannten Bearbeitungsverfahren auf die magnetischen Eigenschaften und Eisenverluste unter Berücksichtigung der Materialparameter wie Korngröße und Legierungsgehalt. Ein Schwerpunkt liegt dabei auf der quantitativen vergleichenden Bewertung der unterschiedlichen Schneidverfahren. Der zweite Teil dieser Arbeit beschäftigt sich mit den Auswirkungen von makroskopischen mechanischen Spannungen, wie sie bei der Montage entstehen, und der Korrelation mit den Auswirkungen des Schneidprozesses. Bei den untersuchten Materialien handelt es sich um großtechnisch hergestellte Seriengüten, welche in elektrischen Antrieben von Hybrid- und E-Fahrzeugen eingesetzt werden. Um den Einfluss des Schneidens zu untersuchen wurde ein experimentelles Verfahren entwickelt, welches sowohl makro- als auch mikromagnetische Untersuchungen kombiniert. Zusätzlich wurden lichtmikroskopische Aufnahmen und Mikrohärtemessungen durchgeführt. Damit die Ergebnisse vergleichbar sind wurde für beide Untersuchungsarten dieselbe Probengeometrie in Form vom Ringkernen gewählt. Für die Untersuchung von makroskopischen Spannungen wurde die feldmetrische Methode mit Streifenproben verwendet, sodass die mechanische Spannung homogen über den Probenquerschnitt anliegt.
Soft magnetic Fe-Al alloys have been a subject of research in the past. However, they never saw the same reception in technical applications as the Fe-Si or Fe-Ni alloys, which is, to some extent, due to a low ductility level and difficulties in manufacturing. Additive manufacturing (AM) technology could be a way to avoid issues in conventional manufacturing and produce soft magnetic components from these alloys, as has already been shown with similarly brittle Fe-Si alloys. While AM has already been applied to certain Fe-Al alloys, no magnetic properties of AM Fe-Al alloys have been reported in the literature so far. Therefore, in this work, a Fe-12Al alloy was additively manufactured through laser powder bed fusion (L-PBF) and characterized regarding its microstructure and magnetic properties. A comparison was made with the materials produced by casting and rolling, prepared from melts with an identical chemical composition. In order to improve the magnetic properties, a heat treatment at a higher temperature (1300 °C) than typically applied for conventionally manufactured materials (850–1150 °C) is proposed for the AM material. The specially heat-treated AM material reached values (HC: 11.3 A/m; µmax: 13.1 × 103) that were close to the heat-treated cast material (HC: 12.4 A/m; µmax: 20.3 × 103). While the DC magnetic values of hot- and cold-rolled materials (HC: 3.2 to 4.1 A/m; µmax: 36.6 to 40.4 × 103) were not met, the AM material actually showed fewer losses than the rolled material under AC conditions. One explanation for this effect can be domain refinement effects. This study shows that it is possible to additively manufacture Fe-Al alloys with good soft magnetic behavior. With optimized manufacturing and post-processing, further improvements of the magnetic properties of AM L-PBF Fe-12Al may still be possible.
The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process
(2020)
In this study, we investigate the use of artificial neural networks as a potentially efficient method to determine the rate capability of electrodes for lithium-ion batteries with different porosities. The performance of a lithium-ion battery is, to a large extent, determined by the microstructure (i.e., layer thickness and porosity) of its electrodes. Tailoring the microstructure to a specific application is a crucial process in battery development. However, unravelling the complex correlations between microstructure and rate performance using either experiments or simulations is time-consuming and costly. Our approach provides a swift method for predicting the rate capability of battery electrodes by using machine learning on microstructural images of electrode cross-sections. We train multiple models in order to predict the specific capacity based on the batteries’ microstructure and investigate the decisive parts of the microstructure through the use of explainable artificial intelligence (XAI) methods. Our study shows that even comparably small neural network architectures are capable of providing state-of-the-art prediction results. In addition to this, our XAI studies demonstrate that the models are using understandable human features while ignoring present artefacts.
Future lunar exploration will be based on in-situ resource utilization (ISRU) techniques. The most abundant raw material on the Moon is lunar regolith, which, however, is very scarce on Earth, making the study of simulants a necessity. The objective of this study is to characterize and investigate the sintering behavior of EAC-1A lunar regolith simulant. The characterization of the simulant included the determination of the phase assemblage, characteristic temperatures determination and water content analysis. The results are discussed in the context of sintering experiments of EAC-1A simulant, which showed that the material can be sintered to a relative density close to 90%, but only within a very narrow range of temperatures (20–30 °C). Sintering experiments were performed for sieved and unsieved, as well as for dried and non-dried specimens of EAC-1A. In addition, an analysis of the densification and mechanical properties of the sintered specimens was done. The sintering experiments at different temperatures showed that the finest fraction of sieved simulant can reach a higher maximum sintering temperature, and consequently a higher densification and biaxial strength. The non-dried powder exhibited higher densification and biaxial strength after sintering compared to the dried specimen. This difference was explained with a higher green density of the non-dried powder during pressing, rather than due to an actual influence on the sintering mechanism. Nevertheless, drying the powder prior to sintering is important to avoid the overestimation of the strength of specimens to be fabricated on the Moon.
Laser melting manufacturing of large elements of lunar regolith simulant for paving on the Moon
(2023)
The next steps for the expansion of the human presence in the solar system will be taken on the Moon. However, due to the low lunar gravity, the suspended dust generated when lunar rovers move across the lunar soil is a significant risk for lunar missions as it can affect the systems of the exploration vehicles. One solution to mitigate this problem is the construction of roads and landing pads on the Moon. In addition, to increase the sustainability of future lunar missions, in-situ resource utilization (ISRU) techniques must be developed. In this paper, the use of concentrated light for paving on the Moon by melting the lunar regolith is investigated. As a substitute of the concentrated sunlight, a high-power CO2 laser is used in the experiments. With this set-up, a maximum laser spot diameter of 100 mm can be achieved, which translates in high thicknesses of the consolidated layers. Furthermore, the lunar regolith simulant EAC-1A is used as a substitute of the actual lunar soil. At the end of the study, large samples (approximately 250 × 250 mm) with interlocking capabilities were fabricated by melting the lunar simulant with the laser directly on the powder bed. Large areas of lunar soil can be covered with these samples and serve as roads and landing pads, decreasing the propagation of lunar dust. These manufactured samples were analysed regarding their mineralogical composition, internal structure and mechanical properties.
Intelligente Lastkollektivoptimierung für Erprobungen von elektrischen und hybriden Antriebssträngen
(2019)
Integrated laser based pre‐tempering at laser welding of AISI 1045 steel by using 3D‐scanner optics
(2021)