About this Abstract |
| Meeting |
MS&T25: Materials Science & Technology
|
| Symposium
|
Sintering and Related Powder Processing Science and Technologies
|
| Presentation Title |
Energy-efficient powder consolidation of Fe-Si magnetic composite via in-situ friction stir forging |
| Author(s) |
Rajib Kalsar, Hrishikesh Das, Shivakant Shukla, Lei Li, Tanvi A. Ajantiwalay, Jacob Haag, Tej Bahadur Chhetri, Bharat Gwalani, Chins Chinnasamy, Vineet V. Joshi |
| On-Site Speaker (Planned) |
Rajib Kalsar |
| Abstract Scope |
Magnetic materials are essential to the performance of electric motors. While laminated soft magnetic materials remain the industry standard, soft magnetic composites (SMC) are increasingly favored for applications involving three-dimensional magnetic flux and high-frequency operations. To address the need for more energy-efficient manufacturing routes, this study explores the use of in-situ friction stir forging (I-FSF) as a novel, single-step consolidation technique for Fe-3.5Si soft magnetic powders. Oxidized powders were utilized to form oxide coatings, which function as insulation layers, enhancing electrical resistivity and reducing magnetic losses. Compared to conventional sintering, I-FSF reduces diffusion time and accelerates densification, enabling near-net-shape fabrication of dense SMC components with improved structural integrity. The consolidated specimens exhibited excellent mechanical properties with tensile strength exceeding 600 MPa, alongside high magnetic performance. These findings demonstrate the viability of I-FSF as an energy-efficient alternative processing method for advanced SMCs in next-generation electric motor applications. |