Liu Lanbing, Ding Chao, Mei Yunhui, Lu Guoquan
The Department of Materials Science and Engineering, Virginia Tech, Blacksburg, VA 24061, USA.
School of Materials Science and Engineering, Tianjin University, Tianjin 300072, China.
Materials (Basel). 2019 Mar 11;12(5):817. doi: 10.3390/ma12050817.
Additive manufacturing (AM), or 3D-printing, has the potential for rapid prototyping of innovative designs of magnetic components used in power electronics converters. In this study, we tailored a silver paste as the metal feedstock of an extrusion 3D printer so that the metal would be compatible with a ferrite paste feedstock for 3D-printing of ferrite magnetic components. We focused on adjusting the metal formulation to match its shrinkage to that of the ferrite and to improve adhesion during the co-sintering process of the printed part. We found that a 5 wt % addition of ferrite powder in the metal paste can achieve matched shrinkage and strong adhesion. Evaluation of the co-sintered magnetic components showed no significant defects, such as cracks, warpage, or delamination, between the metal and ferrite. The shear strength between the two sintered materials was greater than 50 MPa, and the electrical resistivity of the sintered metal winding was less than twice that of the bulk silver, which is lower than those of most 3D-printed winding metals reported in the literature.
增材制造（AM），即3D打印，具有为电力电子转换器中使用的磁性元件创新设计进行快速原型制作的潜力。在本研究中，我们定制了一种银浆作为挤出式3D打印机的金属原料，以便该金属能与用于3D打印铁氧体磁性元件的铁氧体浆料原料兼容。我们着重于调整金属配方，使其收缩率与铁氧体的收缩率相匹配，并在打印部件的共烧结过程中提高附着力。我们发现，在金属浆料中添加5 wt%的铁氧体粉末可实现收缩率匹配和强附着力。对共烧结磁性元件的评估表明，金属与铁氧体之间没有明显缺陷，如裂纹、翘曲或分层。两种烧结材料之间的剪切强度大于50 MPa，烧结金属绕组的电阻率小于块状银的两倍，低于文献中报道的大多数3D打印绕组金属的电阻率。
