| EPSRC Reference: |
EP/Z002524/1 |
| Title: |
New High Performance and Productivity Magnetic Core Coating Process (MAGCoat) |
| Principal Investigator: |
Lavery, Professor NP |
| Other Investigators: |
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| Researcher Co-Investigators: |
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| Project Partners: |
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| Department: |
Faculty of Science and Engineering |
| Organisation: |
Swansea University |
| Scheme: |
Standard Research - NR1 |
| Starts: |
01 August 2024 |
Ends: |
31 July 2025 |
Value (£): |
256,030
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| EPSRC Research Topic Classifications: |
| Electric Motor & Drive Systems |
Manufacturing Machine & Plant |
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Summary on Grant Application Form |
Background and Motivation:
Our project aims to innovate the production of high-quality soft magnetic materials (Fe-Si alloys) with increased silicon content (up to 6.5%). Soft magnetic materials are vital in various electrical devices, including as motor cores in generators and motors. With increasing electrification, demand for efficient materials grows, particularly for electric vehicles (EVs). However, current production methods face limitations in silicon content due to processing difficulties, and state-of-the-art technologies are expensive hindering the take-up of higher silicon materials.
Our project targets this challenge by exploring innovative manufacturing approaches. This advancement in soft magnetic materials will reduce core-losses, and will enable more economical energy-efficient motors thus supporting the global shift towards renewable energy and net-zero emissions. The development of 6.5% silicon electrical steels is an objective of the APC automotive roadmap to reduce the weight of electric vehicles and to extend range / reduce battery size for electric vehicles in line with the UK governments' strategy for low emission road transport.
Research Hypothesis and Objectives:
We aim to develop cost-effective soft magnetic materials through two approaches: the Spray Lamination Process (SLP) and the High Silicon Process (HSP). The target is to achieve an 80% cost reduction compared to current state-of-the-art methods, while maintaining at least 80% peak efficiency These methods involve thermal spray coating technologies together with diffusion annealing to achieve high silicon content. This will be developed at the level of a single laminate, multiple laminates and final as a proof-of-concept core which will all be tested for magentic and mechanical properties.
Outcomes of Programme:
The project addresses current manufacturing limitations, making high-silicon materials economically viable for broader applications, especially in EVs. Successful implementation could lead to significant advancements in energy efficiency and sustainability across industries. Technical risks are mitigated through systematic experimentation and analysis. The project's transformative potential lies in its contribution to reducing energy consumption, enhancing motor efficiency, and facilitating material recycling. Ultimately, this investment could revitalize soft magnetic material manufacturing in the UK, bolstering its position in the EV supply chain and fostering export opportunities.
Overall, our project aims to revolutionize the production of soft magnetic materials, paving the way for more efficient and sustainable electrical devices, particularly in the burgeoning electric vehicle market.
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Key Findings |
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This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
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Potential use in non-academic contexts |
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This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
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Impacts |
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| Description |
This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk |
| Summary |
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| Date Materialised |
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Sectors submitted by the Researcher |
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This information can now be found on Gateway to Research (GtR) http://gtr.rcuk.ac.uk
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| Project URL: |
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| Further Information: |
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| Organisation Website: |
http://www.swan.ac.uk |