3D Printed Metallic Glass Alloy Could Cut Energy Waste in Electric Motors

Keeping Glass Glassy

A European research consortium under the AM2SoftMag project has developed an iron-based metallic glass alloy for 3D printed electric motor components that could reduce energy losses.

The alloy, made from iron, silicon, boron, niobium, and nickel, was developed by researchers at Saarland University. Iron-based metallic glasses have excellent soft magnetic properties, but LPBF printing usually causes unwanted crystallization from repeated heating and cooling cycles.

IMDEA Materials Institute confirmed that the elements in the alloy are distributed randomly for homogeneous mechanical and magnetic properties. Using a double laser scanning strategy with controlled time delays, the alloy prints in a fully amorphous state at over 92% density.

Prof. Maria Teresa Perez Prado of IMDEA Materials said the material's magnetic behavior could significantly improve electric motor efficiency and reduce overall energy waste.

Next, Saarland University and IMDEA will scale manufacturing with UC3M, INRIM, and TU Berlin, testing the alloy in real motor rotor and stator prototypes.

The research was published in Acta Materialia.