The magnetic performance of NdFeB permanent magnets rapidly decreases as their operation temperature increases. This limits the power output of electric motors as their internal temperature quickly increases with the power demand. This is particularly problematic for applications where high peak power is required for a short period of time, for example during automobile highway acceleration or during an airplane lift-off. With the advances in additive manufacturing, one can envision to fabricate more complex motor geometries and magnetic structures, without additional costs, allowing for enhanced functionalities such as better thermal management. In this context, this paper investigates the feasibility of using phase changing materials (PCMs) to mitigate the temperature rise in permanent magnets (PMs) fabricated by additive manufacturing. The potential of PCM and its relevance was validated by modeling the thermal response of an electric motor during a representative electric vehicle driving scenario. It was found that segmented magnets with embedded phase changing materials would allow to efficiently control temperature rise. To validate the simulation results, PM test pieces with and without embedded PCMs were fabricated using cold spray additive manufacturing and tested using a custom laser thermal cycling setup.

This work presents the design and validation of a vibrating coil magnetometer for the characterization of the field dependence of the critical current density of centimeter-sized bulk superconductors as an alternative to the destructive methods typically used. The magnetometer is also shown to be capable of measuring the magnetic moment in an applied field of up to 5 T for diverse magnetic materials, such as soft and hard ferromagnets and high-temperature superconducting pellets. The vibrating coil magnetometer was first optimized using finite element simulations and calibrated using a commercial vibrating sample magnetometer. The vibrating coil magnetometer was benchmarked with hysteresis measurements of a Nd2Fe14B disk made with a commercial hysteresisgraph, showing good agreement between the different setups. The magnetic hysteresis of a YBa2Cu3O7−x superconducting pellet was measured at 77 K, showing a penetration field of 1 T and an irreversibility field of 4 T. The field dependent critical current density of the superconductor was then inferred from the magnetic hysteresis measurements and extrapolated at low fields. Finally, the resulting critical current density was used to successfully reproduce the measured magnetization curve of the pellet at 2 T with finite element simulations.

As cold spray additive manufacturing matures, significant efforts are being made to develop spray conditions for more challenging materials, thereby expanding the technology’s range of applications. One main challenge while using commercially available equipment is that, even under optimized conditions, deposition efficiency remains low for some materials. Powder particles that do not adhere are wasted, which can severely affect the process economics, especially in a mass production context and/or when expensive feedstocks are used. Powder recovery and reuse is a logical solution to mitigate this problem, yet few studies evaluate its feasibility and its impact on powder characteristics and ultimately coating performance. In this work, powder recovery was investigated for two cases: a Ni powder and a NdFeB-Al powder mix, used respectively for repair applications and for the fabrication of permanent magnets. A prototype recovery system was built, achieving a recovery efficiency of up to 75%. The powders were recovered after up to four spray runs, and their morphology and size distribution were characterized. The magnetic properties of both powders and coatings were evaluated using hysteresis measurements. Although the process affects the particle size distribution and their magnetic properties, powders remain suitable for re-deposition for both materials. In particular, it was shown that NdFeB-Al mix maintains 97% of its initial magnetic performance under industrial operating conditions.