Development of a three-phase synchronous electric machine via powder metallurgy

The developments achieved by electric machines in recent decades were more significant in terms of their resizing and in the ways in which they are activated than in the field of materials used for their manufacture. The electric machine project proposes the improvement of the technology of a three-phase synchronous machine through changes in the material and in the manufacturing process of the rotor and stator cores. Cores were constructed from four different materials: laminated sheets, Fe2%P alloy, commercial soft magnetic composite material and soft magnetic composite material developed using iron and phosphoric acid (H3PO4). The machines were tested as generators on a test bench. The use of the powder metallurgy manufacturing process to obtain cores of electrical machines proved to be a viable alternative to the traditional method of making the cores of electrical machines. However, the results of operating tests at different frequencies pointed to yields below 86% for the laminated core machine against 42% for the Fe2%P alloy, 38% for Somaloy and 41% for the developed material.